Rockwell Automation Allen-Bradley DriveGuard B Series Bedienungsanleitung

User Manual

Original Instructions

Safe Torque Off Option (Series B)

for PowerFlex 40P and PowerFlex 70

Enhanced Control AC Drives

Catalog Number 20A-DG01

Topic Page

Summary of Changes 2

General Description 3

What Is the DriveGuard Safe Torque Off Option? 3

Certifications and Compliance 4

CE Certification 5

Certified Equipment 6

Important Safety Considerations 6

Safe State 7

Safety Category 3 / PL (d) Performance Definition 7

Stop Category Definitions 8

Performance Level and Safety Integrity Level (SIL) CL2 8

PFDavg and PFH Definitions 8

PFDavg and PFH Data 9

Functional Proof Tests 10

Contact Information if Safety Option Failure Occurs 10

Installation and Wiring 11

Pre-Installation Instructions 11

EMC Considerations 12

DriveGuard Safe Torque Off Option Installation 13

Wiring 16

Verify Operation 17

Description of Operation 19

PowerFlex 40P Safe Torque Off Operation 19

PowerFlex 70 Safe Torque Off Operation 20

Connection Examples 21

2Rockwell Automation Publication PFLEX-UM003D-EN-P - June 2021

Summary of Changes

Change See Page…

Updated Certifications and Compliance sections 5

Rockwell Automation Publication PFLEX-UM003D-EN-P - June 2021 3

General Description

The DriveGuard® Safe Torque Off option, when used with PowerFlex® 40P or

PowerFlex 70 drives together with other safety components, provides a safety

function which inhibits torque generation in the motor(s) powered by the drive. When

used with PowerFlex 40P or PowerFlex 70 drive, the DriveGuard Safe Torque Off option

has been certified to meet the requirements for SIL 2 according to EN/IEC 61800-5-2

and IEC 61508, and PL (d) and Category 3 according to EN ISO 13849-1. 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 safeguarding.

What Is the DriveGuard Safe Torque Off Option?

The DriveGuard Safe Torque Off option:

• Provides the “Safe torque off (STO)” function defined in EN/IEC 61800-5-2.

• Blocks gate firing signals from reaching the IGBT output power devices of the

drive. This prevents the IGBT’s from switching in the sequence necessary to

generate torque in the connected motor.

• Can be used in combination with other safety devices to fulfill the requirements

of a system “safe torque off” function which satisfies Category 3 / PL (d)

according to EN ISO 13849-1 and SIL CL 2 according to EN/IEC 62061, IEC 61508,

and EN/IEC 61800-5-2.

IMPORTANT

This option is suitable for performing only mechanical work on the drive

system or affected area of a machine. It does NOT disconnect or isolate the

drive power output to the motor.

This option should not be used as a control for normal starting and/or

stopping the drive.

4Rockwell Automation Publication PFLEX-UM003D-EN-P - June 2021

General Description

Certifications and Compliance

TUV Rheinland EC Type Examination Certification

TUV Rheinland has certified the DriveGuard Safe Torque Off option, when used in a

PowerFlex 70 or PowerFlex 40P drive, is compliant with the requirements for

machines defined in Annex I of the EC Directive 2006/42/EC, and that it complies with

the requirements of the relevant standards listed below.

• EN ISO 13849-1 Safety of machinery - Safety related parts of control systems -

Part 1: General principles for design

(DriveGuard Safe Torque Off option + drive achieves Category 3 / PL (d))

• EN/IEC 61800-5-2 Adjustable speed electrical power drive systems - Part 5-2

Safety requirements - Functional

(DriveGuard Safe Torque Off option + drive achieves SIL CL 2)

• EN/IEC 62061 Safety of machinery - Functional safety of safety-related electrical,

electronic and programmable electronic control systems

• IEC 61508 Part 1-7 Functional safety of electrical/electronic/programmable

electronic safety-related systems

TUV also certifies that the DriveGuard Safe Torque Off option may be used in

applications up to Category 3 / PL (d) according to EN ISO 13849-1 and SIL 2 according

to EN/IEC 62061 / IEC 61508 / EN/IEC 61800-5-2.

TUV Rheinland certifications may be found at rok.auto/certifications.

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 (see

your drive 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 IGBT's 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 PFLEX-UM003D-EN-P - June 2021 5

General Description

UL Certification

The PowerFlex 40P, PowerFlex 70, and DriveGuard Safe Torque Off option have been

listed with UL as compliant with UL 508C.

Canadian Certification

The PowerFlex 40P, PowerFlex 70, and DriveGuard Safe Torque Off option have been

listed (cUL) as compliant with C22.2 No 14.

RCM Certification

Rockwell Automation declares the PowerFlex 40P (240V AC, 480V AC), PowerFlex 70

(240V AC, 400V AC, 480V AC), and DriveGuard Safe Torque Off option compliant with

the Radiocommunications Act:1992 (including Amendments up to 2018), the

Radiocommunications (Electromagnetic Compatibility) Standard 2017, and the

Radiocommunications Labeling (Electromagnetic Compatibility) Notice 2017 as

demonstrated by compliance with IEC 61800-3 Adjustable speed electrical power

drive systems Part 3: EMC requirements and specific test methods.

CE Certification

LV Directive 2014/35/EU

Rockwell Automation declares the PowerFlex 40P and PowerFlex 70 drives compliant

with the CE LV Directive as demonstrated by compliance with the requirements of

EN 61800-5-1 Adjustable speed electrical power drive systems - Part 5-1: Safety

requirements - Electrical, thermal, and energy. The DriveGuard Safe Torque Off Option

Kit is not within the scope of the Low Voltage Directive.

EMC Directive 2014/30/EU

Rockwell Automation declares the PowerFlex 40P (240V AC, 480V AC), PowerFlex 70

(240V AC, 400V AC, 480V AC), and DriveGuard Safe Torque Off option compliant with

the CE EMC Directive as demonstrated by compliance with the requirements of

EN 61800-3 Adjustable speed electrical power drive systems Part 3: EMC requirements

and specific test methods.

Machinery Directive 2006/42/EC

TUV Rheinland, Notified Body Identification Number 0035, certifies the DriveGuard

Safe Torque Off option compliant with the CE Machinery Directive as demonstrated by

compliance with the requirements of EN ISO 13849-1, EN/IEC 61800-5-2, and

EN/IEC 62061.

TIP If the encoder interface option is installed on the PowerFlex 70, the product will not

have CE certification.

6Rockwell Automation Publication PFLEX-UM003D-EN-P - June 2021

General Description

Certified Equipment

Certifications Online

See the Product Certifications link at rok.auto/certifications. for Declarations of

Conformity, Certificates, and other certifications details.

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.

Drive Rating (AC) TUV Certified

DriveGuard Safe Torque

Off Function

PowerFlex 40P 240V Yes Series B or greater

480V Yes Series B or greater

PowerFlex 70

Enhanced Control 240V Yes Series A or greater

400V Yes Series A or greater

480V Yes Series A or greater

ATTENTION: Hazard of injury exists due to electric shock. Only install a Series

B or greater DriveGuard Safe Torque Off option in a PowerFlex 40P Drive.

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 PFLEX-UM003D-EN-P - June 2021 7

General Description

Safe State

The DriveGuard Safe Torque Off option is intended for use in safety-related

applications where the de-energized state is the safe state. All of the examples in the

Description of Operation section are based on achieving the de-energization as the

safe state.

Safety Category 3 / PL (d) Performance Definition

To achieve Safety Category 3 / PL (d) 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.

• 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 EN ISO 13849-2, these

cables must be installed so as to be protected against external damage by cable

ducting or armor.

• Whenever reasonably practical a single fault shall be detected at or before the

next demand of the safety function.

• The average diagnostic coverage of the safety-related parts of the control

system shall be low.

• The mean time to dangerous failure of each of the redundant channels shall be

low to high.

8Rockwell Automation Publication PFLEX-UM003D-EN-P - June 2021

General Description

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 21.

• 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 2 on page 22.

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/IEC 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.

See the EN ISO 13849-1, IEC 61508, and EN/IEC 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.

IMPORTANT

When designing the machine application, timing and distance should be

considered for a coast to stop:

•Stop Category 0 or Safe Torque Off

•Stop Category 1 or Safe Stop 1 - Time Controlled

For more information regarding stop categories, see EN/IEC 60204-1 or IEC

61800-5-2.

Rockwell Automation Publication PFLEX-UM003D-EN-P - June 2021 9

General Description

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 probability of a dangerous failure occurring 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.

PowerFlex 40P

PFDavg and PFH for 20-year Proof Test Interval

PowerFlex 70

PFDavg and PFH for 20-year Proof Test Interval

Terminology

Attribute Test Result

PFDavg 1.74E-05

PFH 2.0E-10

SFF 81%

Attribute Test Result

PFDavg 3.4E-05

PFH 3.9E-10

SFF 81%

Abbreviation Full Term Definition

PFDavg Probability of

Failure on

Demand

The average probability of a system to fail to perform

its design function on demand.

PFH Probability of

Failure per Hour The probability of a system to have a dangerous failure

occur per hour.

SFF Safe Failure

Fraction The sum of safe failures plus the sum of dangerous

detected failures divided by the sum of all failures.

10 Rockwell Automation Publication PFLEX-UM003D-EN-P - June 2021

General Description

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.

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.

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