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Rockwell PowerFlex 70 Safety Application Manual

Safe-off control ethernet/ip guard i/o safety module and integrated safety controller
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Download this manual See also: User Manual
Safety Application Example
PowerFlex 70 Safe-Off Control
EtherNet/IP Guard I/O Safety Module and
GuardLogix Integrated Safety Controller
Safety Rating: Category 3 (also see
Achieving a Cat. 4
Safety
Rating) according to EN954-1
Introduction...........................................................................................2
Important User Information..................................................................2
General Safety Information..................................................................3
Description ............................................................................................4
Setup and Wiring ..................................................................................5
Configure...............................................................................................8
Programming ......................................................................................13
Performance Data ...............................................................................17
Achieving a Cat. 4 Safety Rating .......................................................19
Additional Resources.........................................................................22

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Summary of Contents for Rockwell PowerFlex 70

  • Page 1: Table Of Contents

    Safety Application Example PowerFlex 70 Safe-Off Control EtherNet/IP Guard I/O Safety Module and GuardLogix Integrated Safety Controller Safety Rating: Category 3 (also see Achieving a Cat. 4 Safety Rating) according to EN954-1 Introduction...................2 Important User Information..............2 General Safety Information..............3 Description ....................4 Setup and Wiring ..................5...

  • Page 2: Introduction

    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.

  • Page 3: General Safety Information

    Safety circuits must take into consideration safety distance calculations which are not part of the scope of this document. Contact Rockwell Automation to find out more about our safety risk assessment services. Publication SAFETY-AT017B-EN-P-July 2011...

  • Page 4: Description

    Description This application example shows how to control a PowerFlex 70 drive with DriveGuard Safe-Off, via a GuardLogix integrated safety controller and an EtherNet/IP Guard I/O safety module. An emergency stop pushbutton and a Trojan gate interlock switch are used as safety inputs within this safety system.

  • Page 5: Setup And Wiring

    For detailed information on installing and wiring, refer to the product manuals listed in the Additional Resources. System Overview GuardLogix Controller EtherNet/IP Guard I/O EtherNet/IP Fault Reset PowerFlex 70 with DriveGuard Emergency Stop Circuit Reset Trojan Interlock Switch Wiring This diagram shows the appropriate wiring. Publication SAFETY-AT017B-EN-P-July 2011...
  • Page 6 This input must be controlled by the Guard I/O Safety module. The Drive Enable digital input on the PowerFlex 70 drive is a solid state circuit. For this reason, the safety outputs on the Guard I/O safety module must not be configured for Safety Pulse Test as it may interfere with the operation of the digital input.
  • Page 7 Reaction to Faults Based on the wiring and safety module configuration shown in this application example, this section details how the safety module responds to line faults incurred between the safety outputs and the PowerFlex 70 drive: Channel-to-channel Short Channel...

  • Page 8: Configure

    Adjust the three switches on the front of the module. • Use a Dynamic Host Configuration Protocol (DHCP) server, such as Rockwell Automation BootP/DHCP Server Utility. • Retrieve the IP address from nonvolatile memory. Using the Rotary Switches to Set the Network IP Address The module reads the switches first to determine if the switches are set to a valid number.
  • Page 9 The DHCP server also assigns other transport control protocol (TCP) parameters. Using the Rockwell Automation BootP/DHCP Server Utility Follow these steps to use the Rockwell Automation BootP/DHCP Server Utility to set the Network IP Address. 1. Identify the target module by the MAC address listed on the EtherNet/IP Guard I/O safety module.
  • Page 10 Configuring the 1791ES-IB8XOBV4 Guard I/O Safety Module in RSLogix 5000 Software In the RSLogix 5000 project, the 1791ES-IB8XOBV4 module is added to the I/O Configuration under the 1756-ENBT EtherNet/IP bridge module, as shown. Set the Module Properties The 1791ES-IB8XOBV4 module is configured as follows. 1.
  • Page 11 2. Click Change to open the Module Definition dialog box. 3. Configure the module as shown below. Combined Status consolidates all eight input status bits into a single status bit. The same is true for Output Data. For status bits for individual input/output/test points, choose an alternative Input/Output Status data format.
  • Page 12 These are not safety inputs so they are configured as Standard. 6. Select Input 7 to monitor the feedback from the Safe-Off relay in the PowerFlex 70 drive. This is a Standard input. Edit the Module’s Test Output Configuration 1.

  • Page 13: Programming

    Safety Accelerator Toolkit for GuardLogix Systems publication, IASIMP-QS005. This toolkit provides easy-to-use system design, programming, and diagnostic tools to assist you in the rapid development and deployment of your safety systems using Rockwell Automation’s GuardLogix controller, Guard I/O, and safety devices. Publication SAFETY-AT017B-EN-P-July 2011...
  • Page 14 Safety Tags The safety logic shown below requires the creation and use of the following safety tags. Safety Logic The following code should be programmed in a routine within your Safety Task in the GuardLogix controller. Emergency Stop Safety Logic The E-stop instruction provides SIL 3 level diagnostics for a dual- channel emergency stop function.
  • Page 15 within this instruction, a dummy tag named None is used as a placeholder. Input status is not monitored because the input data will go LO if the channel faults. The safety code in the safety output routine will prevent outputs from restarting if the E-stops reset automatically.
  • Page 16 Safety Input Interlock Rung This rung includes the safety device input interlocks, with tag names Sts_Zone1_EStop_InputOK and Sts_Zone1_GateSwitch_InputOK, that energize the Sts_Zone1_InputsOK OTE instruction. These interlock tags are driven by the individual safety device input logic rungs shown earlier. The Sts_Zone1_InputsOK tag is then included in the Output Enable Rung which drives the ROUT instruction.

  • Page 17: Performance Data

    CellGuard1. The ROUT instruction outputs, O1 and O2, are used to drive the safety outputs 06 and 07 (Tags: CellGuard1:O.Pt06Data and CellGuard1:O.Pt07Data) which are wired to the PowerFlex 70 Safe-Off relay and Drive Enable digital input. Reassignment of the feedback and output channels must be made to match your unique safety wiring configuration.
  • Page 18 Worst case, the time it takes to occur is the sum of the A to E path as described below. A – Input Module Delay – 16 ms + on/off delay filters B – Input Connection Reaction Time Limit (CTRL) The Connection Reaction Time Limit is configured in the 1791ES Module Properties within RSLogix 5000 software.

  • Page 19: Achieving A Cat. 4 Safety Rating

    Typical Reaction Time of Safety System Typically, both channels are HI coming from the interlock switch and the E-stop. If any one channel goes LO, the corresponding filter timer configured in the 1791ES-IB8OBV4 module starts. If the channel is still LO when the filter times out, the output is turned OFF.
  • Page 20 Modified Bill of Materials A Cat. 4 solution requires a safety contactor which disconnects power to the motor that the PowerFlex 70 is controlling under a hazardous condition. Catalog Number Description Quantity 100S-C43DJ14BC Bulletin 100S Safety Contactor Choose a safety contactor that is rated for your application requirements.
  • Page 21 Modified Configuration The safety Output Configuration for the Guard I/O module can now be configured for Safety Pulse Test. With Safety Pulse Test configured, shorts of the P terminal to 24V and shorts of the M terminal to 0V can be detected during system operation.

  • Page 22: Additional Resources

    System Design Tools available on the Quick Start Publication IASIMP-QS005 SAFETY-CL002 CD You can view or download publications at http://literature.rockwellautomation.com. To order paper copies of technical documentation, contact your local Rockwell Automation distributor or sales representative. Publication SAFETY-AT017B-EN-P – July 2011...
  • Page 23 Notes: Publication SAFETY-AT017B-EN-P-July 2011...
  • Page 24 Allen-Bradley, ControLogix, DriveGuard, GuardLogix, PowerFlex, and Rockwell Automation are trademarks of Rockwell Automation, Inc. Trademarks not belonging to Rockwell Automation are property of their respective companies. Publication SAFETY-AT017B-EN-P – July 2011 Publication SAFETY-AT017B-EN-P – July 2011 Supersedes publication SAFETY-AT017A-EN-P – July 2008...

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