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.

Rockwell Automation Publication 20D-UM007H-EN-P - August 2019 11
General Description Chapter 1
Safety Category 3 Performance Definition
To achieve Safety Category 3 according to EN ISO 13849-1, the
safety-related parts have to be designed such that:
• the safety-related parts of machine control systems and/or their protective
equipment, as well as their components, shall be designed, constructed,
selected, assembled, and combined in accordance with relevant standards
so that they can withstand expected conditions.
• basic and well-tried safety principles shall be applied.
• a single fault in any of its parts does not lead to a loss of safety function.
• some but not all faults will be detected.
• the accumulation of undetected faults can lead to loss of safety function.
• short circuits in the 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 immediate removal of power to the
actuator, resulting in an uncontrolled coast to stop. See “Description of
Operation” Example 1 on page 31 and Example 2 on page 32.
• Stop Category 1 is achieved with power available to the machine actuators
to achieve the stop. Power is removed from the actuators when the stop is
achieved. See “Description of Operation” Example 3 on page 33.
IMPORTANT
When designing the machine application, timing and distance should
be considered for a coast to stop (Stop Category 0 or Safe Torque Off).
For more information regarding stop categories, refer to EN 60204-1.

12 Rockwell Automation Publication 20D-UM007H-EN-P - August 2019
Chapter 1 General Description
Performance Level and Safety Integrity Level (SIL) CL2
For safety-related control systems, Performance Level (PL), according to
EN ISO 13849-1, and SIL levels, according to IEC 61508 and EN 62061,
include a rating of the system’s ability to perform its safety functions. All of
the safety-related components of the control system must be included in both
a risk assessment and the determination of the achieved levels.
Refer to the EN ISO 13849-1, IEC 61508, and EN 62061 standards for
complete information on requirements for PL and SIL determination.
PFDavg and PFH Definitions
Safety-related systems can be classified as operating in either a Low Demand
mode, or in a High Demand/Continuous mode.
• Low Demand mode: where the frequency of demands for operation made
on a safety-related system is no greater than one per year or no greater
than twice the proof-test frequency.
• High 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 probability of
failure on demand (PFDavg). The SIL value for a High Demand/Continuous
mode safety-related system is directly related to the average frequency of a
dangerous failure per hour (PFH).
PFDavg and PFH Data
These PFDavg and PFH calculations are based on the equations from Part 6
of IEC 61508 and show worst-case values.
This table provides data for a 20-year proof test interval and demonstrates the
worst-case effect of various configuration changes on the data.
PFDavg and PFH for 20-year Proof Test Interval
Attribute Test Result Frames 1…6 Test Result Frames 9…14
PFDavg 5.28 x 10-5 2.14 x 10-4
PFH 6.00 x 10-10 1/h
(calculated according to IEC 61508) 2.64 x 10-9 1/h (calculated according to IEC 61508)
MTTFDHigh (4023 years) High (11415 years)
DCav low (69%) low (80%)

Rockwell Automation Publication 20D-UM007H-EN-P - August 2019 13
General Description Chapter 1
Functional Proof Tests
The functional safety standards require that functional proof tests be
performed on the equipment used in the system. Proof tests are performed at
user-defined intervals and are dependent upon PFDavg and PFH values.
See Veri f y Op eratio ns 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 analysis (if necessary) to determine the probable cause of
the failure.
IMPORTANT
Your specific application determines the time frame for the proof test
interval.

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

Rockwell Automation Publication 20D-UM007H-EN-P - August 2019 15
Chapter 2
Installation and Wiring
Care should be taken to follow drive instructions for EMC and
environmental compliance. Refer to the following list of manuals for specific
instructions:
• PowerFlex® 700L Liquid-Cooled Adjustable Frequency AC Drive,
publication 20L-UM001
• PowerFlex 700S Adjustable Frequency Drive - Phase II Control, Frames
1…6, publication 20D-IN024
• PowerFlex 700H Adjustable Frequency AC Drive and PowerFlex 700S
High Performance AC Drive, Frames 9...14, publication PFLEX-IN006
Pre-Installation Instructions
Installation must be in accordance with the following steps and must be
carried out by competent personnel. The 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 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.

16 Rockwell Automation Publication 20D-UM007H-EN-P - August 2019
Chapter 2 Installation and Wiring
Option Board Installation
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)

Rockwell Automation Publication 20D-UM007H-EN-P - August 2019 17
Installation and Wiring Chapter 2
PowerFlex 700S Frames 9…14
1. Remove the I/O Control Cassette from 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

18 Rockwell Automation Publication 20D-UM007H-EN-P - August 2019
Chapter 2 Installation and Wiring
PowerFlex 700S, All Frames, 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.

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.

20 Rockwell Automation Publication 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)