Rockwell Automation Allen-Bradley PowerFlex 750 ATEX Series User manual

User Manual Original Instructions
PowerFlex 750-Series ATEX
Option Module
Catalog Number 20-750-ATEX

2Rockwell Automation Publication 750-UM003G-EN-P - November 2022
PowerFlex 750-Series ATEX Option Module User Manual
Important User Information
Read this document and the documents listed in the additional resources section about installation, configuration, and operation of this equipment before
you install, configure, operate, or maintain this product. Users are required to familiarize themselves with installation and wiring instructions in addition to
requirements of all applicable codes, laws, and standards.
Activities including installation, adjustments, putting into service, use, assembly, disassembly, and maintenance are required to be carried out by suitably
trained personnel in accordance with applicable code of practice.
If this equipment is used in a manner not specified by the manufacturer, the protection provided by the equipment may be impaired.
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.
These labels may also be on or inside the equipment to provide specific precautions.
The following icon may appear in the text of this document.
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 a hazard, and recognize the consequence.
IMPORTANT Identifies information that is critical for successful application and understanding of the product.
SHOCK HAZARD: Labels may be on or inside the equipment, for example, a drive or motor, to alert people that dangerous
voltage may be present.
BURN HAZARD: Labels may be on or inside the equipment, for example, a drive or motor, to alert people that surfaces may
reach dangerous temperatures.
ARC FLASH HAZARD: Labels may be on or inside the equipment, for example, a motor control center, to alert people to
potential Arc Flash. Arc Flash will cause severe injury or death. Wear proper Personal Protective Equipment (PPE). Follow ALL
Regulatory requirements for safe work practices and for Personal Protective Equipment (PPE).
Identifies information that is useful and can help to make a process easier to do or easier to understand.

Rockwell Automation Publication 750-UM003G-EN-P - November 2022 3
Table of Contents
Preface
Summary of Changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Chapter 1
Safety Concepts ATEX Directive 2014/34/EU and UKEx Regulations
(2016 No. 1107) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Motor Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
About the PowerFlex 750-Series ATEX Option Module . . . . . . . . . . 9
Using the PowerFlex 750-Series ATEX Option Module with an
11-series I/O Option Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Catalog Numbers for ATEX and 11-Series I/O Option
Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Catalog Numbers for Spare Terminal Plugs. . . . . . . . . . . . . . . . . . 10
ATEX System and UKEx System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
ATEX Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Thermostat Trip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Positive Temperature Coefficient (PTC) Trip . . . . . . . . . . . . . . . 12
Safe State . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Hardware Fault Tolerance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Safety Reaction Time. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Contact Information If Safety Option Failure Occurs . . . . . . . . . . . . 13
Chapter 2
Installation and Wiring Perform a Risk Assessment of the Operational Environment. . . . . . 15
Perform a Safety Analysis of the Motor. . . . . . . . . . . . . . . . . . . . . . . . . . 16
Remove Power to the System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Access the Control Pod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Configure the Hardware. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
S1 Switch Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Safety Enable Jumper Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
ATEX Option Module and 11-Series I/O Option Module
without a Safety Option Module. . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
ATEX Option Module and 11-Series I/O Option Module
with a Safety Option Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Assemble the ATEX and 11-Series I/O Option Modules . . . . . 23
Connect the Thermal Sensor Wires. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Cabling Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Installation Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Install the ATEX Option Module Assembly. . . . . . . . . . . . . . . . . . . . . 25
PowerFlex 750-Series Safe Torque Off Option Wiring . . . . . . . . . . . 27
Safe Speed Monitor Option Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Integrated Safety - Safe Torque Off Option Module. . . . . . . . . . . . . . 29
PowerFlex 755/755T Integrated Safety Functions Option Module 30
Reset the Drive after an SSM Fault Detection. . . . . . . . . . . . . . . . . . . . 30

4Rockwell Automation Publication 750-UM003G-EN-P - November 2022
Table of Contents
Interface Without a Safety Option. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Chapter 3
Verify Operation Description of Functionality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Motors with Thermostatic Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Functional Proof Testing for Systems with Thermostat
Contacts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Motors with Positive Temperature Coefficient (PTC) Devices. . . . 33
Functional Proof Testing for Systems with PTC Devices. . . . . . 33
Functional Proof Testing without a Test Fixture. . . . . . . . . . . . . . . . . 34
Chapter 4
ATEX Monitoring Parameter 41 [ATEX Sts]. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
ATEX Fault Descriptions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
ATEX Configuration Errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Restart the Drive after an Over-temperature Fault . . . . . . . . . . . . . . . 39
Appendix A
Specifications and
Certifications
General Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
11-Series I/O Option Module Terminal Block Specifications . . . . . 41
Safety Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Environmental Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Certifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

Rockwell Automation Publication 750-UM003G-EN-P - November 2022 5
Preface
Summary of Changes This manual contains new and updated information as indicated in the following
table.
Introduction Use this manual if you are responsible for designing, installing, configuring, or
troubleshooting applications that use the PowerFlex® 750-Series ATEX option
module. The 20-750-ATEX option module applies to the following PowerFlex
750-Series drives:
• PowerFlex 755TL low harmonic, non-regenerative drives
• PowerFlex 755TR regenerative drives
• PowerFlex 755TM drive systems with regenerative bus-supplies and
common-bus inverters
• PowerFlex 755TS AC drives
• PowerFlex 755 AC drives
• PowerFlex 753 AC drives
Throughout this manual, PowerFlex 755T drive products are used to refer to
PowerFlex 755TL drives, PowerFlex 755TR drives, and PowerFlex 755TM drive
systems.
Topic Page
Changed ATEX to Ex throughout the publication Throughout
Added UKEx Regulations (2016 No. 1107) to heading 7
Added UKEx Regulations (2016 No. 1107) to Motor Requirements 8
Changed EN 50281-1-1, or according to IEC 61241-1 to EN 60079-31 8
Added UKEx System to heading 10
Changed DIN 440 to DIN 44082 12
Changed IEC 60947-8or EN to EN/IEC 12, 41
Changed EC-Type-Examination to EU-Type-Examination under ATEX directive 43
Added UKCA (United Kingdom) to Certifications table 43
IMPORTANT Read and understand this user manual before you begin to design and
install your ATEX system.

6Rockwell Automation Publication 750-UM003G-EN-P - November 2022
Preface
Notes:

Rockwell Automation Publication 750-UM003G-EN-P - November 2022 7
Chapter 1
Safety Concepts
The PowerFlex® ATEX option module that is installed in a PowerFlex 750-Series
drive or PowerFlex 755T drive products and equipped with an 11-Series I/O
option module provides an ATEX-compliant safety function. This ATEX-
compliant function provides a safe turn-off for equipment that is installed in a
potentially explosive atmosphere according to 2014/34/EU.
ATEX Directive 2014/34/EU
and UKEx Regulations
(2016 No. 1107)
The PowerFlex 750-Series drives and PowerFlex 755T drive products, together
with the ATEX and 11-Series I/O option modules, are compliant safety devices
under the ATEX Directive and UKEx Regulations, and satisfy requirements for
use in Group II, Category 2, (GD) applications with ATEX approved motors as
described here:
• Group II – The motor is installed in a potentially explosive atmosphere
that is not in a mine.
• Category 2 – The motor is likely to be exposed to an explosive atmosphere.
A high level of protection is required.
• GD – The explosive atmosphere consists of a mixture of (G) gas vapors
and (D) dust that can cause an explosion.
Certification of the drive for the ATEX group and category on its nameplate is
based on installation, operation, and maintenance according to these items:
•Thisusermanual
• The requirements in the drive user manual and installation instructions
•Theinstructionmanualforthemotor
Topic Page
ATEX Directive 2014/34/EU and UKEx Regulations (2016 No. 1107) 7
Motor Requirements 8
ATEX System and UKEx System 10
ATEX Function 11
Safe State 12
Hardware Fault Tolerance 12
Safety ReactionTime 13
Contact Information If Safety Option Failure Occurs 13

8Rockwell Automation Publication 750-UM003G-EN-P - November 2022
Chapter 1 Safety Concepts
Motor Requirements • The motor must be manufactured under the guidelines of the ATEX
Directive 2014/34/EU and UKEx Regulations (2016 No. 1107). The
motor must be installed, operated, and maintained according to the
instructions of the motor manufacturer.
• Only motors with nameplates that are marked for use on an inverter power
source, and labeled for specific hazardous areas, can be used in hazardous
areas on inverter (variable frequency) power.
• When the motor is rated ATEX Group II, Category 2 for use in gas
environments (category 2G), the motor must be of flameproof
construction, or Ex d (according to EN 60079-1). Group II motors are
marked with a temperature or a temperature code.
• When the motor is rated ATEX Group II, Category 2 for use in dust
environments (category 2D), you must protect the motor with an
enclosure (according to EN 60079-31: Ex tD). Group II motors are
marked with a temperature.
• The motor over-temperature signal is supplied to the drive by one of two
methods:
– A normally closed contact (open during over temperature condition)
compatible with the digital (logic) input circuitry of the drive. If
multiple sensors are required in the motor, the connection at the drive
must be the result of all required contacts that are wired in series.
– A positive temperature coefficient (PTC) type of thermal sensor. See
Appendix A for specifications.
•Seeallproductmarkingsforadditionalcautions.
• Typical motor markings are contained on a motor certification nameplate
similar to the sample here.
ATTENTION: Follow all procedures in the standard installation and user
manuals for the ATEX-certified drive with an ATEX-certified motor.You must
also follow all additional instructions in this PowerFlex 750-Series ATEX
Option Module User Manual. Equipment damage and/or personal injury can
result if all additional instructions in this user manual are not followed.
FLAMEPROOF Exd ENCLOSURE
Exd I/IIB Tamb C to C
II 2 G/D
I M2 Sira ATEX
MFG. BY ROCKWELL AUTOMATION
0035

Rockwell Automation Publication 750-UM003G-EN-P - November 2022 9
Chapter 1 Safety Concepts
About the PowerFlex
750-Series ATEX Option
Module
The PowerFlex ATEX option module and the 11-Series I/O option module for
PowerFlex 750-Series AC drives and PowerFlex 755T drive products are safety
system components of the equipment and protective systems. The option
modules are intended for equipment that is used in potentially explosive
atmospheres (Ex). Perform a risk assessment and safety analysis of the operating
atmosphere and the ATEX system components before you begin this Ex
installation:
• PowerFlex 750-Series drive
• PowerFlex 755TL low harmonic drives (1)
• PowerFlex 755TR regenerative drives (1)
• PowerFlex 755TM drive systems (1)
• PowerFlex 755TS AC drives
• Motor
•ATEXoptionmodule
• 11-Series I/O option module
Using the PowerFlex 750-Series ATEX Option Module with an
11-series I/O Option Module
The ATEX option module with the 11-Series I/O option module enables a
PowerFlex 750-Series drive and PowerFlex 755T drive products to be used in Ex
installations. The ATEX option module helps to reduce the risk of explosion due
to an over-temperature condition in an Ex approved motor. In an Ex installation,
the motor is installed in a potentially explosive atmosphere, while the drive is
installed outside of the potentially explosive atmosphere. See Figure 1.
(1) Throughout this manual, the PowerFlex 755TL low harmonic drives, PowerFlex 755TR regenerative drives, and PowerFlex 755TM
drive systems are also referred to as PowerFlex 755T drive products.
WARNING: Risk of Explosion.
Do not install the PowerFlex 750-Series drive or PowerFlex 755T drive products
in a potentially explosive atmosphere.
A drive that is installed in a potentially explosive atmosphere can cause an
explosion.

10 Rockwell Automation Publication 750-UM003G-EN-P - November 2022
Chapter 1 Safety Concepts
Catalog Numbers for ATEX and 11-Series I/O Option Modules
This table lists the catalog numbers for the ATEX option module and the
compatible 11-Series I/O option modules.
Catalog Numbers for Spare Terminal Plugs
This table contains the catalog numbers for the 11-Series I/O option module
spare terminal plug kits.
ATEX System and UKEx
System
The overall system includes an Ex certified motor that is installed in a potentially
explosive atmosphere. The motor is equipped with a thermal sensor that is
connected to the ATEX option input. Do not install the drive in a potentially
explosive atmosphere. See Figure 1.
ATEX Option Module Cat. No. 11-Series I/O Option Module
Cat. No.
Description
20-750-ATEX
20-750-1132D-2R 115V AC digital input
Two relay outputs, digital
20-750-1133C-1R2T 24V DC digital input
Two transistor outputs, one relay output,
digital
20-750-1132C-2R 24V DC digital input
Two relay outputs, digital
Cat. No. Spare Terminal Plug Kit
SK-R1-SCRWTB-EIO Screw-down terminal plugs spare kit (set of three)
SK-R1-SPRGTB-EIO Spring-clamp terminal plugs spare kit (set of three)
WARNING: Risk of Explosion.
Do not install the PowerFlex 750-Series drive or PowerFlex 755T drive products
in a potentially explosive atmosphere.
A drive that is installed in a potentially explosive atmosphere can cause an
explosion.