Allen-Bradley PowerFlex 700S User manual

DriveGuard™
Safe-Off Option for
PowerFlex®700S Phase II
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.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 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.
Important: Identifies information that is critical for successful application and
understanding of the product.
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.
WARNING: Identifies information about practices or circumstances
that can cause an explosion in a hazardous environment, which may
lead to personal injury or death, property damage, or economic loss.
ATTENTION: Identifies information about practices or circumstances
that can lead to personal injury or death, property damage, or economic
loss. Attentions help you:
•identify a hazard
•avoid the hazard
•recognize the consequences
Shock Hazard labels may be located on or inside the equipment (e.g.,
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.

Table of Contents
Section Page
General Description 2
What Is the PowerFlex Safe-Off Option? 2
Safety of Machinery Standards 3
CE Conformity 3
Approved Equipment 3
Installation and Wiring 4
Option Board Installation 5
Wiring 11
Configure Hardware Enable 12
Configure Digital Outputs 13
Linking Parameters 13
Verify Operation 14
Description of Operation 15
Supplemental Information 18
Certification 18

2General 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.
The PowerFlex Safe-Off option:
•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.
•Can be used in combination with other safety devices to provide
Category 0 (Coast) stop according to EN 60204-1 and NFPA 79.
•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.
What Is the PowerFlex Safe-Off Option?
!
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
The Safe-Off with Second Encoder option meets the following safety
standards:
•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
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.
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 & 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
Safety of Machinery Standards
CE Conformity
Approved Equipment

4Installation 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 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 5
1. Remove the I/O Control Cassette from the drive.
Option Board Installation
Task Description
Open the door of the power structure and disconnect the cables that connect to
the main board
Loosen screws on face of cassette
Remove the cassette
A
B
C
B
C
A

6Installation and Wiring
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.
Important: If the Safe-Off option is removed from the drive, this
jumper must be reinstalled or the drive will not run.
16
15

Installation and Wiring 7
4. Remove the exterior cassette covers to access the grounding plate.
➊
➋

8Installation and Wiring
5. Install the 16-pin stacker connector.
6. Plug the Safe-Off with Second Encoder into the 16-pin connector.
7. Install and tighten mounting screws.
0.8-1.1 N-m
(7.0-10.0 lb.-in.)

Installation and Wiring 9
8. Install the exterior cassette covers.
➊
➋

10 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.)
FIELD INSTALLED OPTIONS
Firmware #: Date
Firmware
20-HIM
28-IO-
20-COMM-
20B_-DB1-
HIM
I/O
COM Module
Internal Dynamic Brake
#: Date

Installation and Wiring 11
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).
Safe-Off with Second Encoder Terminal Block Specifications
Wire Types
Safe-Off Terminals 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 +24V DC Connections for user supplied power
to energize coil.
33.3 mA typical, 55 mA maximum.
2 24V Common
3 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
4Common-N.C.
12345678910 131211
BAR CODE LABEL
ASSEMBLY
ID LABEL
123456

12 Installation and Wiring
Ensure that Jumper P22 on the Main Control Board is set to HW Enable
(Pins 2 and 4).
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-UM006, for wiring examples.
Configure Hardware Enable
= HW Enable
= No HW Enable
Jumper P22
12
34
12
34

Installation and Wiring 13
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. Set Par 147 [FW Functions En], Bit 14 “Digital Outs” to 1 (True).
2. Set Par 845 [Dig Out1 Sel], 850 [Dig Out2 Sel] or 855 [Rly Out3
Sel] to option 0 “User Select”.
3. Link Par 846 [Dig Out1 Data], 851 [Dig Out2 Data] or 856 [Rly
Out3 Data] to Par 324 [Fault Status 2]. See “Linking Parameters”
below.
4. Set Par 847 [Dig Out1 Bit], 852 [Dig Out2 Bit] or 857 [Rly Out3 Bit]
to 12. Par 324 Bit 12 = EnableHealth status.
Use the following procedure to establish a link between Par 846 [Dig
Out1 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.
2. Using the HIM keypad, enter 846, 850, or 856 and press the Enter
key. The parameter value screen will appear.
3. Press ALT and then View (Sel). Next, press the Up or Down Arrow
to change “Present Value” to “Defined Link.” Press the Enter key.
4. 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.
5. To remove a link, repeat the steps above and change the source
parameter to zero (0).
Configure Digital Outputs
Linking Parameters

14 Installation and Wiring
At regular intervals during the life of the machine check the safety
function for proper operation. Both safety channels shall 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.
Verify Operation
Safety Function
Status
Drive In
Safe State
Drive In
Safe State
Drive In
Safe State
Drive Able
To Ru n
Safety Channel Operation
Safe-Off Option
Terminals 1 & 2
No Power
Applied
Power Applied No Power
Applied
Power Applied
PowerFlex 700S
Enable Input
No Power
Applied
No Power
Applied
Power Applied Power Applied
Description For Verification
Safe-Off Option
Monitor Contact
Terminals 3 & 4
Closed Open Closed Open
PowerFlex 700S
Drive Inhibits
Param. 156, Bits 1 & 16
Bit 16 = 0
Bit 1 = 1
Bit 16 = 0
Bit 1 = 1
Bit 16 = 1
Bit 1 = 0
Bit 16 = 0
Bit 1 = 0

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-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
+24V DC
PowerFlex 700S
AC Drive
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

16 Description of Operation
Example 1
Safe-Off Connection with Coast-to-Stop Action, Dual Channel
Figure 2 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 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.
Stop
Start
A1 S21 S13 31 13 23 X1
A2
+24V DC
Common
+24V DC
S22 S14 32 14 24 X2
Minotaur
MSR9T
GuardMaster
Troj an
Gate
+24V DC
PowerFlex 700S
AC Drive
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

Description of Operation 17
Example 2
Safe-Off Connection with Controlled Stop Action, Dual Channel
Figure 3 Stop Category 1 – Controlled
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 & 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 & 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 reveals the fault
condition to the operator.
+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 700S
AC Drive
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

18 Supplemental Information
Supplemental Information
Certification
TÜV Industrie Service GmbH
Automation, Software und Informationstechnologie
ZERTIFIKAT Nr./No. 968/EZ 189.00/05
CERTIFICATE
Prüfgegenstand/ Adjustable Frequency AC Drive
Product tested
Zertifikatsinhaber/ Rockwell Automation
License holder 6400 West Enterprise Drive
Hersteller/ USA-Mequon, WI 53092
Manufacture United States of America
Typbezeichnung/
Type designation
Allen Bradley PowerFlex 700S AC Drive
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
Verwendungszweck/ Safety relevant applications;
Intended application Safety Function “Safe stand-
still” according to EN 954-1
category 3
Prüfgrundlagen/
Codes and standards forming
the basis of testing
EN 954-1:1996
EN ISO 13849-2:2003
EN 60204-1:1997
EN 50178:1997
EN 61800-3:1996 & A11:2000
Prüfungsergebnis/
Test results
The safety function “Safe standstill” meets the requirements for
category 3 according EN 954-1.
Besondere Bedingungen/
Specific requirements
Fault exclusion for the external wiring has to be made according to
EN ISO 13849-2.
The user manual “Safe Off Option for PowerFlex 700S AC Drive” has to
be considered.
Der Prüfbericht-Nr. 968/EZ 189.00/05 vom 2005-02-25 ist Bestandteil
dieses Zertifikates.
Der Inhaber eines für den Prüfgegenstand gültigen Genehmigungs-
Ausweises ist berechtigt, die mit dem Prüfgegenstand übereinstimmen-
den Erzeugnisse mit dem abgebildeten Prüfzeichen 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.
2005-02-25
Datum/Date Firmenstempel/Company seal Unterschrift/Signature