Allen-Bradley PowerFlex 525 Application Technique

Safety function: actuator subsystems - stop category 1, drives with safe torque-off

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Original instructions manual (48 pages)

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Summary of Contents for Allen-Bradley PowerFlex 525

Page 1: Table Of Contents
Safety Function: Actuator Subsystems – Stop Category 1 via the PowerFlex 525 and PowerFlex 527 Drives with Safe Torque-off Products: Guardmaster Dual-input Safety Relay, Guardmaster Multifunction-delay Expansion Module, PowerFlex 525 Drive, PowerFlex 527 Drive Safety Rating: CAT. 3, PLd to ISO 13849-1: 2008...
Page 2: Important User Information
Safety Function: Actuator Subsystems – Stop Category 1 via the PowerFlex 525 and PowerFlex 527 Drives with Safe Torque-off 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.
Page 3: General Safety Information
Safety Function: Actuator Subsystems – Stop Category 1 via the PowerFlex 525 and PowerFlex 527 Drives with Safe Torque-off General Safety Information Contact Rockwell Automation to find out more about our safety risk assessment services. IMPORTANT This application example is for advanced users and assumes that you are trained and experienced in safety system requirements.
Page 4: Stop Safety Functions
Safety Function: Actuator Subsystems – Stop Category 1 via the PowerFlex 525 and PowerFlex 527 Drives with Safe Torque-off control reliable. Each safety product has its own rating and can be combined to create a safety function that meets or exceeds the PLr.
Page 5: Functional Safety Description
Safety Function: Actuator Subsystems – Stop Category 1 via the PowerFlex 525 and PowerFlex 527 Drives with Safe Torque-off The vendor must provide probability of failure per hour (PFH) and all relevant functional safety data for all the subsystems of this...
Page 6: Bill Of Material
Safety Function: Actuator Subsystems – Stop Category 1 via the PowerFlex 525 and PowerFlex 527 Drives with Safe Torque-off Bill of Material This Logic and Output subsystems in this document use these products. Cat. No. Description Quantity 440R-D22R2 Guardmaster dual-input safety relay (DI) 440R-EM4R2D Guardmaster multifunction-delay expansion module, 4 N.O.
Page 7 Safety Function: Actuator Subsystems – Stop Category 1 via the PowerFlex 525 and PowerFlex 527 Drives with Safe Torque-off Safety Distance Calculations Detailed calculation of a proper safety distance is beyond the scope of this document, but some considerations follow.
Page 8 Safety Function: Actuator Subsystems – Stop Category 1 via the PowerFlex 525 and PowerFlex 527 Drives with Safe Torque-off The sum response/reaction time of the Guardmaster dual-input safety relay, Guardmaster multifunction-delay expansion module, Guardmaster multifunction-delay expansion module delay, and PowerFlex drive, and worst-case, coast-to-stop portion of the overall system-stopping performance is the same regardless of the input device used.
Page 9 Electrical Schematic In this application example, a local Start/Stop button is directly wired to the PowerFlex 525 drive. This button is used for normal, non-safety stops and starts of the system. It is also used to start/restart the drive after safety-related stops once the safety circuit is reset.
Page 10 Safety Function: Actuator Subsystems – Stop Category 1 via the PowerFlex 525 and PowerFlex 527 Drives with Safe Torque-off This document presumes that a Stop/Start button is connected to the system PAC. It is referred to in Figure 2, but is not part of this circuit.
Page 11: Configuration
Safety Function: Actuator Subsystems – Stop Category 1 via the PowerFlex 525 and PowerFlex 527 Drives with Safe Torque-off Configuration Configure the Guardmaster Dual-input Safety Relay Follow these steps to configure the Guardmaster dual-input safety relay. For more information about this relay, refer to Guardmaster Safety Relay DI Installation Instructions, publication 440R-IN037.
Page 12 Safety Function: Actuator Subsystems – Stop Category 1 via the PowerFlex 525 and PowerFlex 527 Drives with Safe Torque-off 1. Start configuration/overwrite: With power off, turn the Range rotary switch to 0 and power up the unit. Range After the power-up test, the PWR/Fault status indicator will flash red.
Page 13: Calculation Of The Performance Level
PowerFlex 520-Series Adjustable Frequency AC Drive User Manual, publication 520-UM001 Both the PowerFlex 525 and PowerFlex 527 drives ship with the STO feature disabled by jumpers. Refer to the appropriate user IMPORTANT manual for guidance on removing these jumpers.
Page 14 Safety Function: Actuator Subsystems – Stop Category 1 via the PowerFlex 525 and PowerFlex 527 Drives with Safe Torque-off The functional safety data for the SensaGuard switch, Guardmaster dual-input safety relay, Guardmaster multifunction- delay expansion module, and PowerFlex 525 drive is provided from the Rockwell Automation® SISTEMA library. The functional safety data for the PowerFlex 527 drive is from the PowerFlex 527 Adjustable Frequency AC Drive User Manual, publication 520-UM002.
Page 15 Safety Function: Actuator Subsystems – Stop Category 1 via the PowerFlex 525 and PowerFlex 527 Drives with Safe Torque-off This can be modeled as follows: Output Logic Guardmaster Guardmaster PowerFlex Multifunction-delay Dual-input 527 Drive Expansion Module Safety Relay Subsystem 3...
Page 16 Safety Function: Actuator Subsystems – Stop Category 1 via the PowerFlex 525 and PowerFlex 527 Drives with Safe Torque-off The two PowerFlex 525 safety functions each achieve their necessary PLr. When the PowerFlex 527 drive is used in the safety function, "Safety-related stop function initiated by a safeguard, " the SISTEMA calculation results are as follows.
Page 17: Verification And Validation Plan
OSSD devices might be unique to those devices. The responses of the PowerFlex 527 drive and the PowerFlex 525 drive to faults on their STO inputs are the same. Therefore, the following tests, using purposely-created faults, are appropriate for either drive.
Page 18 Safety Function: Actuator Subsystems – Stop Category 1 via the PowerFlex 525 and PowerFlex 527 Drives with Safe Torque-off Confirm that the Guardmaster dual-input safety relay is set to the proper Logic configuration setting "2." Confirm that the Guardmaster multifunction-delay expansion module is set to the proper Range configuration setting "1"...
Page 19 Safety Function: Actuator Subsystems – Stop Category 1 via the PowerFlex 525 and PowerFlex 527 Drives with Safe Torque-off Open and close the guarded door. The IN1 and IN2 status indicators must be steady green. The OUT status indicator must blink green.
Page 20 Safety Function: Actuator Subsystems – Stop Category 1 via the PowerFlex 525 and PowerFlex 527 Drives with Safe Torque-off Validation of Safe Response to Abnormal Operation - The safety system responds properly to all foreseeable faults with corresponding diagnostics. Guardmaster Dual-input Safety Relay- Guardmaster Multifunction-delay Expansion Module Tests...
Page 21 Safety Function: Actuator Subsystems – Stop Category 1 via the PowerFlex 525 and PowerFlex 527 Drives with Safe Torque-off Close the gate. Press and release the Reset button. The Guardmaster dual-input safety relay and the Guardmaster multifunction-delay expansion module reset. The PowerFlex drive does not respond to the Start button.
Page 22: Additional Resources
Safety Function: Actuator Subsystems – Stop Category 1 via the PowerFlex 525 and PowerFlex 527 Drives with Safe Torque-off Additional Resources These documents contain additional information about related products from Rockwell Automation Resource Description SensaGuard Rectangular Flat Pack Installation Instructions, publication 440N-IN008 Provides instructions on how to install a SensaGuard switch.
Page 23 Safety Function: Actuator Subsystems – Stop Category 1 via the PowerFlex 525 and PowerFlex 527 Drives with Safe Torque-off Notes: Rockwell Automation Publication SAFETY-AT140A-EN-P - May 2015...
Page 24 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, Connected Components Workbench, Guardmaster, LISTEN. THINK. SOLVE, PowerFlex, Rockwell Automation, Rockwell Software, SensaGuard, and Studio 5000 Automation Engineering & Design Environment are trademarks of Rockwell Automation, Inc Trademarks not belonging to Rockwell Automation are property of their respective companies.

This manual is also suitable for:

Powerflex 527 Guardmaster dual-input safety relay Guardmaster multifunction-delay expansion module