Rockwell Automation Allen-Bradley DriveGuard 20D-P2-DG01 User manual

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

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.
Labels may also be on or inside the equipment to provide specific precautions.
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 consequences.
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).

Rockwell Automation Publication 20D-UM007H-EN-P - August 2019 3
Table of Contents
Summary of Changes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Chapter 1 General Description
What Is the DriveGuard Safe Torque Off Option? . . . . . . . . . . . . . . . 7
Safety of Machinery Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Safety Certifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Evaluation/Certification by TÜV Rheinland Group . . . . . . . . . . 9
Certifications Online. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Important Safety Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Safety Category 3 Performance Definition . . . . . . . . . . . . . . . . . . . . . 11
Stop Category Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Performance Level and Safety Integrity Level (SIL) CL2. . . . . . . . . 12
PFDavg and PFH Definitions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
PFDavg 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
PowerFlex 700S Frames 1…6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
PowerFlex 700S Frames 9…14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
PowerFlex 700L Frames 3A and 3B . . . . . . . . . . . . . . . . . . . . . . . . . 24
Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Configure Hardware Enable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Configure Digital Outputs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Linking Parameters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Verify Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Chapter 3 Description of Operation
DriveGuard Safe Torque Off Operation. . . . . . . . . . . . . . . . . . . . . . . . 29
Connection Examples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

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

Rockwell Automation Publication 20D-UM007H-EN-P - August 2019 5
Summary of Changes
This manual contains new and updated information.
New and Updated Information
The following changes apply to this revision of the manual.
Change See Page…
Updated front cover to current style –
Changed PFD to PFDavg in all cases - incorrect term was applied –
Updated the Important statements in front cover to current 2
Updated years in the Safety of Machinery Standards 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 torque value to step 8 21
Updated Configure Digital Outputs 27
Updated Linking Parameters 27
Added PowerFlex 700L frame 2 drive to example 32
Expanded description of Fault Detection 34
Changed part number on publication and updated back cover –

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

Rockwell Automation Publication 20D-UM007H-EN-P - August 2019 7
Chapter 1
General Description
The DriveGuard® Safe Torque Off option, when used with other safety
components, helps provide protection to meet the requirements for SIL CL2
and Category 3 or PL d class applications. Safety requirements are based on
the standards current at the time of certification.
The DriveGuard Safe Torque 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.
What Is the DriveGuard Safe Torque Off Option?
The DriveGuard Safe Torque 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 62061 Performance Level PL d and Category 3
according to EN ISO 13849-1.
IMPORTANT
This option is suitable for performing mechanical work on the drive
system or affected area of a machine only. It does not provide
electrical safety. For electrical maintenance on the drive and/or motor,
equipment must be electrically disconnected from the power source.
The Safe Torque Off option should not be used for non safety-related
stopping of the drive.

8Rockwell Automation Publication 20D-UM007H-EN-P - August 2019
Chapter 1 General Description
Safety of Machinery Standards
The DriveGuard Safe Torque Off option meets the following council
directives and the requirements of the following machine safety standards:
• EN 61800-5-2 Adjustable Speed Electrical Power Drives Systems – Part
5-2 Safety Requirements: Functional
• EN ISO 13849-1 Safety of Machinery – Safety-related parts of control
systems - Part 1: General Principles for Design
• EN 62061 + A1 Safety of Machinery, Functional safety of safety-related
electrical, electronic and programmable electronic control systems
• EN 60204-1 + A1 Safety of Machinery – Electrical equipment of
machines – Part 1: General Requirements
• IEC 61508 Part 1-7 Functional safety of electrical / electronic /
programmable electronic safety-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 or
test points (refer to your drive’s User Manual for locations). The voltage
must be zero.
ATTENTION: In Safe Torque 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.
ATTENTION: In the event of the failure of two output IGBTs in the
drive, when the DriveGuard Safe Torque Off option has controlled the
drive outputs to the off state, the drive may provide energy for up to
180° of rotation in a 2-pole motor before torque production in the
motor ceases.

Rockwell Automation Publication 20D-UM007H-EN-P - August 2019 9
General Description Chapter 1
Safety Certifications
The TÜV Rheinland group has approved the DriveGuard Safe Torque Off
option for use in safety-related applications where the de-energized state is
considered to be the safe state. All of the examples related to I/O included in
this manual are based on achieving de-energization as the safe state for typical
Machine Safety and Emergency Shutdown (ESD) systems.
Evaluation/Certification by 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 Phase II Frames 1…6
208/240V and 400/480V
Frames 5 and 6
600/690V
Frames 9…14
400/480V and 600/690V
TUV Certificate No. 01/205/5195.01/17
TUV Report No. 968EZ 189.03/17
PowerFlex 700L
Liquid-Cooled Frames 2, 3A, and 3B
400/480V and 600/690V
TUV Certificate No. 01/205/0667.01/15
TUV Report No. 968/EZ 230.03/15

10 Rockwell Automation Publication 20D-UM007H-EN-P - August 2019
Chapter 1 General Description
Important Safety Considerations
The system user is responsible for:
• the set-up, safety rating, and validation of any sensors or actuators
connected to the system.
• completing a system-level risk assessment and reassessing the system any
time a change is made.
• certification of the system to the desired safety performance level.
• project management and proof testing.
• programming the application software and the safety option
configurations 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.
IMPORTANT
When applying Functional Safety, restrict access to qualified,
authorized personnel who are trained and experienced.
ATTENTION: When designing your system, consider how personnel
will exit the machine if the door locks while they are in the machine.
Additional safeguarding devices may be required for your specific
application.