Related Manuals for Allen-Bradley PowerFlex 7000 Series
Summary of Contents for Allen-Bradley PowerFlex 7000 Series
- Page 1 User Manual Original Instructions PowerFlex 7000 Series Safe Torque Off Bulletin Numbers 7000A, 7000, 7000L...
- Page 2 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.
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Page 3: Table Of Contents
Table of Contents Preface Summary of Changes ......... . . 5 Abbreviations . - Page 4 Table of Contents Appendix A Specifications Introduction ..........35 General Specifications .
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Page 5: Preface
Preface This manual explains how PowerFlex® 7000 drives with Safe Torque Off option can be used in Safety Integrity Level (SIL) CL3, Performance Level [PLe], or Category 3 (Cat. 3) applications. It describes the safety requirements, including PFD and PFH values and application verification information, and provides information on installing, configuring, and preventative maintenance of the Safe Torque Off option. -
Page 6: Additional Resources
PowerFlex 7000 Medium Voltage AC Drive (C Frame) - ForGe Control (Marine) You can view or download publications at http:/www.rockwellautomation.com/literature/. To order paper copies of technical documentation, contact your local Allen-Bradley® distributor or Rockwell Automation® sales representative. Rockwell Automation Publication 7000-UM203C-EN-P - September 2018... -
Page 7: What Is The Powerflex 7000 Drive Safe Torque Off Option
Chapter General Description The Safe Torque Off option is intended to be applied as a component in a safety control system. Components in the system must be chosen and applied appropriately to achieve the desired level of operational safety. What Is the PowerFlex 7000 The PowerFlex™... -
Page 8: Safety Standards Applied To Safe Torque Off Option
Chapter 1 General Description Safety Standards Applied To The Safe Torque Off option satisfies applicable requirements in the following standards related to functional and machinery safety. Safe Torque Off Option • IEC 61508-1 to 7: 2010 • EN 61800-5-1: 2007 •... -
Page 9: Introduction
Chapter Safety Concept Introduction This section describes the safety performance level concept and how the PowerFlex™ 7000 drives can meet the requirements for SIL CL3, Cat. 3, or PLe applications. Safety Certification The PowerFlex 7000 drive safety option is certified for use in safety applications up to and including SIL 3 according to EN 61800-5-2, IEC 61508, and EN 62061, PLe, and Cat. -
Page 10: Safety Cat. 3 Performance Definition
Chapter 2 Safety Concept ATTENTION: The drive should never be considered in a safe state unless the safety function is active. 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. -
Page 11: Performance Level And Safety Integrity Level (Sil) Cl3
Safety Concept Chapter 2 Performance Level and Safety Integrity Level (SIL) CL3 For safety-related control systems, Performance Level (PL), according to 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. -
Page 12: Reliability Data For 12-Year Mission Time Test
Chapter 2 Safety Concept Reliability Data for 12-year Mission Time Test Attribute Value 2.26 E-8 1/hour SIL CL Category MTTF 803 years PTI (Proof Test Interval) (1) STO data for all medium voltage drive frames. Safe State The Safe State encompasses all operation that occurs outside of the other monitoring and stopping behavior of the drive as defined as part of the normal operation without the Safe Torque Off Option. -
Page 13: Contact Information If Safety Option Failure Occurs
Safety Concept Chapter 2 Contact Information if Safety If you experience a failure with any safety-certified device, contact your local Rockwell Automation distributor. With this contact, you can: Option Failure Occurs • return the components to Rockwell Automation so the failure is appropriately logged for the catalog number affected and a record is made of the failure. - Page 14 Chapter 2 Safety Concept Notes: Rockwell Automation Publication 7000-UM203C-EN-P - September 2018...
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Page 15: Powerflex 7000 Drive Safe Torque Off Operation
Chapter Operation, Installation, and Wiring PowerFlex 7000 Drive Safe The PowerFlex™ 7000 Drive Safe Torque Off option disables the rectifier and inverter SGCTs by removing the power supply to the fiber optic transmitters Torque Off Operation that command the devices to turn on, and disabling the gating signals to those fiber optic transmitters. - Page 16 Chapter 3 Operation, Installation, and Wiring ATTENTION: By itself, the PowerFlex 7000 Drives Safe Torque Off option initiates a coast-to-stop action. Additional protective measures will need to be applied when an application requires a different stopping action. IMPORTANT The status of the MV drive input device must be configured and connected correctly to the safety system to prevent faults being generated.
- Page 17 Operation, Installation, and Wiring Chapter 3 Operating Principle The drive implements a dual channel system interface using an Allen-Bradley™ Minotaur™ MSR127 safety relay unit. Opening the gate door will switch the input circuits to the safety relay (Figure 2). The output circuits of the safety relay will signal each OIBBS (one for the rectifier bridge and one for the inverter bridge) to go to the safe state.
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Page 18: Wiring
Chapter 3 Operation, Installation, and Wiring Wiring Wiring to the safety components in the drive must be in accordance with the following steps and must be carried out by competent personnel. Important points to remember about control wiring: • Always use tinned copper wire. •... - Page 19 (1) Additional relay for STO is mounted in the LV starter cabinet. When using an Allen-Bradley Bulletin 1512 starter or if the starter is built into the drive, a relay is added (CNT_AUX_RLY) and wired for the STO option to generate the proper logic required to meet the feedback requirements.
- Page 20 Breaker Feedback A dry contact is supplied that must be inserted to either the emergency stop input of the starter (in the case of an internal/external Allen-Bradley or customer-supplied starter) or the undervoltage dropout circuit if the drive input isolation device is a circuit breaker. The terminal points are DI-14A and DI-1.
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Page 21: Product Compatibility
Operation, Installation, and Wiring Chapter 3 Figure 6 - Timing Diagram Drive Input Isolation Device Feedback (wire 509A) MV Applied Interlock contact to input device (wire DI-14A) 0.5 s max. 2 cycles max. 1 s max. Product Compatibility The STO option is not compatible with these PowerFlex 7000 configurations: •... -
Page 22: Sps Jumper Settings
Chapter 3 Operation, Installation, and Wiring Figure 7 - Functional Safety Mode Table 5 - Parameter Settings Group Parameter Name Status Drive Hardware Group Number of Devices (P145/P146) Number of installed OIB2s Rectifier Type (P153) 6 PWM Bypass Contactor (Hardware Options 1 – P141) Unchecked Redundant Devices (Hardware Options 1 –... -
Page 23: Verify Operation
15. Perform these procedures after the drive commissioning procedure is complete. IMPORTANT The input component of the STO system in the drive is an Allen-Bradley Minotaur MSR127 Safety Relay. Perform an STO functional test at least once every six months to maintain the safety rating. - Page 24 Chapter 3 Operation, Installation, and Wiring This procedure involves causing a demand for the safety function. Verify that 1 second after the demand for the safety function, the following is true: Table 7 - STO Activation Complete? Description Both channels on the MSR127 safety relay switch off. CH1 and CH2 status indicators must switch OFF when a demand for the safety function is...
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Page 25: Sto System Components Location
Chapter System Components STO System Components The location of the 24STO option components is the same for all PowerFlex™ 7000 drive frame sizes and configurations (Figure 8). The STO Location system components are mounted on a DIN rail in the Low Voltage cabinet above the Control Board Panel and shown in detail in Figure 9. - Page 26 Chapter 4 System Components Figure 8 - Safe Torque Off Option Location for 24STO STO System Components Optical Interface Boards 2 (OIB2) Optical Interface Base Board Safety (OIBBS) Hinged Panel (open) Figure 9 - STO System Components Detail Safety Relay Supplementary (440R-N23132) Protector (PN-D165417)
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Page 27: Optical Interface Boards 2
System Components Chapter 4 Figure 10 - Safe Torque Off Option Location for 24STORK Optical Interface Boards 2 (OIB2) (PN-271938) Optical Interface Base Board Safety (OIBBS) (PN-504125) STO System Components Optical Interface Boards 2 The Optical Interface (OIB2) Boards are the interface between the DPM/ OIBBS and the Gate Driver circuitry. - Page 28 Chapter 4 System Components Figure 11 - Optical Interface Board The OIB2 boards are mounted directly on the Optical Interface Base Board Safety (OIBBS) using two parallel 14-pin connectors for the electrical connection, and metal standoffs to provide the mechanical support. There is one OIBBS for the inverter, and one OIBBS for the rectifier devices.
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Page 29: Replace Optical Interface Board 2
System Components Chapter 4 There are three status indicators on the OIB2. The following table illustrates the status and description for the status indicator states: Status Indicator Status Description Red – On Run – The OIB2 has received an Enable signal. The drive control software is in control of all gating. - Page 30 Chapter 4 System Components Figure 12 - Optical Interface Base Board Safety (OIBBS) Rockwell Automation Publication 7000-UM203C-EN-P - September 2018...
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Page 31: Replace Optical Interface Base Board Safety
System Components Chapter 4 There are six status indicators on the OIBBS. Table 9 - Status Indicators Status Status Description Indicator Board has no power. Green Normal operating condition Diagnostic processor watchdog timeout or power supply faults Flashing Normal operation Green Diagnostic processor faulted Yellow –... -
Page 32: Optical Interface Base Board Safety Test Points
Chapter 4 System Components Optical Interface Base Board Safety Test Points In addition to the command and diagnostic test points, there are three ground reference test points. These reference points are electrically identical, but their locations facilitate oscilloscope or chart recorder test leads connections. Table 10 - OIBBS Test Points Test Point Signal Name... - Page 33 System Components Chapter 4 Table 10 - OIBBS Test Points Test Point Signal Name Description TP36 DIAG_15 OIB2 C, RX4 Diagnostic Feedback TP37 CMD_15 OIB2 C, TX4 Firing Command Signal TP38 DIAG_16 OIB2 C, RX5 Diagnostic Feedback TP39 CMD_16 OIB2 C, TX5 Firing Command Signal TP40 DIAG_17 OIB2 C, RX6 Diagnostic Feedback...
- Page 34 Chapter 4 System Components Notes: Rockwell Automation Publication 7000-UM203C-EN-P - September 2018...
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Page 35: Introduction
Appendix Specifications Introduction This appendix provides general specifications for the PowerFlex™ 7000 drive Safe Torque Off Option module. General Specifications Table 1 - General Specifications Attribute Value Standards EN 60204-1, IEC 61508, EN 61800-3, EN 61800-5-1, EN 61800-5-2, EN 62061, EN ISO 13489 Safety category Cat. -
Page 36: Certifications
Appendix A Specifications Certifications See the Product Certification link at www.rockwellautomation.com/products/ certification/ for Declarations of Conformity, Certificates, and other certifications details. Certification Value c-UL-us UL Listed, certified for US and Canada. European Union 2004/108/EC EMC Directive, compliant with: EN 61800-3; PowerFlex 7000 AC Drive, Emissions and Immunity EN 62061;... - Page 37 This declaration of conformity is issued under the sole responsibility of the manufacturer. Object of the declaration: Allen-Bradley PowerFlex 7000 Safe Torque Off Options (reference the attached list of catalogue numbers) The object of the declaration described above is in conformity with the relevant Union harmonisation legislation:...
- Page 38 Appendix A Specifications Notes: Rockwell Automation Publication 7000-UM203C-EN-P - September 2018...
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Page 39: Spare Parts
Appendix Spare Parts and Preventative Maintenance Spare Parts Part No. Description Quantity PN-504125 Optical Interface Base Board Safety (OIBBS) PN-271938 Optical Interface Board (OIB2) PN-35744 Safety Industrial Relay 440R-N23132 Safety Relay 1606-XLP50E XLP 50 W Power Supply ATTENTION: In addition to the restart procedure in the user manual, perform the Verify Operation procedures on page 23 after replacing any of these... -
Page 40: Rockwell Automation Publication 7000-Um203C-En-P - September
Appendix B Spare Parts and Preventative Maintenance Notes: Rockwell Automation Publication 7000-UM203C-EN-P - September 2018... - Page 42 Rockwell Automation maintains current product environmental information on its website at http://www.rockwellautomation.com/rockwellautomation/about-us/sustainability-ethics/product-environmental-compliance.page. Allen-Bradley, IntelliVAC, Minotaur, PanelView, PowerFlex, Rockwell Automation, and Rockwell Software are trademarks of Rockwell Automation, Inc. Trademarks not belonging to Rockwell Automation are property of their respective companies.