Allen-Bradley Armor PowerFlex AC Drives User Manual
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This manual links to Armor PowerFlex AC Drive Fault Codes Reference Data, publication 35-RD002 and to Armor PowerFlex AC Drive CIP Objects and Attributes Reference Data, publication 35-RD001; download the spreadsheet now for offline access. Armor PowerFlex AC Drives Bulletins 35E, 35S User Manual Original Instructions Armor PowerFlex AC Drives User Manual 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. 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 consequence. IMPORTANT Identifies information that is critical for successful application and understanding of the product. These labels may also be on or inside the equipment to provide specific precautions. 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). The following icon may appear in the text of this document. Identifies information that is useful and can help to make a process easier to do or easier to understand. 2 Rockwell Automation Publication 35-UM001G-EN-P - September 2024 Table of Contents Preface About This Publication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Summary of Changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Conventions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Access Fault Code and CIP Object and Attribute Data . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Download Firmware, AOP, EDS, and Other Files . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Terminology. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Additional Resources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 CE and UKCA Conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Machinery Directive (2006/42/EC)/2008 No. 1597 Supply of Machinery (Safety) Regulations (MD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 EMC Directive (2014/30/EU)/2016 No. 1091 Electromagnetic Compatibility Regulations (EMC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 LVD Directive (2014/35/EU)/2016 No. 1101 Electrical Equipment (Safety) Regulations (LV) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 RoHS Directive (2011/65/EU)/2012 No. 3032 RoHS Regulations (RoHS) . . . . . . . . . . 14 Ecodesign Directive (2019/1781/EU)/2021 No. 745 Ecodesign for Energy-Related Products Regulations (Eco) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Chapter 1 Armor PowerFlex Variable Frequency Drives Overview Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Input and Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Frame Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Safety Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Location of Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Catalog Number Explanation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Required Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Motor Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Control Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Velocity Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Flying Start. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Motor Thermal Overload . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Fault Auto Reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Safe Torque Off and Safe Monitor Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Standard Encoder Operation and Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Group Motor Application. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Local Disconnect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 EMI Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Dynamic Brake Resistor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Power Input Gland. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Factory-installed Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Internal Power Supply. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Electromechanical Brake. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Typical Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Standard Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Armor PowerFlex 35E Drive with NFPA 70 Emergency Stop. . . . . . . . . . . . . . . . . . . 29 Rockwell Automation Publication 35-UM001G-EN-P - September 2024 3 Table of Contents Safety Drives Configuration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Chapter 2 Install the Armor PowerFlex Drive Unpack and Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Storage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Personal and Electrical Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Precautions for Cold Temperature Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 Precautions for Motor Start/Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 Avoid Electrostatic Discharge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 Environmental Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 Lift Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 Lift and Mount the Drive. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 Mounting Orientation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 Armor PowerFlex Drive Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Wiring and Workmanship Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 Electromagnetic Compatibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 Cabling and Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 Ethernet Cable Ferrite Cores . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 Configuration Constraints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 Product Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 Shielding and Grounding of Motors and Motor Cables . . . . . . . . . . . . . . . . . . . . . . . 49 Power Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 Add Line Reactor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 Branch Circuit Protection Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 Group Motor Installations for USA and Canada Markets. . . . . . . . . . . . . . . . . . . . . . 50 Auxiliary Power Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 Power Supply Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 Field Earth Jumper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 Internal Power Supply Wiring and Local Disconnect Behavior . . . . . . . . . . . . . . . . 54 Single External Power Supply Wiring and Local Disconnect Behavior . . . . . . . . . . 54 Multiple External Power Supply Wiring and Local Disconnect Behavior. . . . . . . . . 54 Power Terminal Location and Internal Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 Connector Pinouts and Cable Torques. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 Power and Motor Connector Pinouts and Cable Torques. . . . . . . . . . . . . . . . . . . . . 57 Standard I/O Connector Pinouts and Cable Torques . . . . . . . . . . . . . . . . . . . . . . . . 58 Safety I/O Connector Pinouts and Cable Torques. . . . . . . . . . . . . . . . . . . . . . . . . . . 59 Ethernet Connector Pinouts and Cable Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 Encoder Connector Pinouts and Cable Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 Encoder Wiring Examples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 ArmorConnect Media . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 Local Disconnect Behavior . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 Electronic Motor Disconnect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67 Chapter 3 EtherNet/IP Operation 4 Set the IP Address. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 Set the IP Address using Rotary Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 Set the IP Address using the BOOTP/DHCP Server Utility. . . . . . . . . . . . . . . . . . . . . 73 Set the IP Address using the FactoryTalk Linx Application . . . . . . . . . . . . . . . . . . . 75 Rockwell Automation Publication 35-UM001G-EN-P - September 2024 Table of Contents Change IP Address after Safety Device is Configured . . . . . . . . . . . . . . . . . . . . . . . . . . . 77 Device Level Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 Protected Operations Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 Ethernet Communication Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81 Chapter 4 Keypad Operation Keypad Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84 Local/Auto (Local Motor Control) Modes Operation. . . . . . . . . . . . . . . . . . . . . . . . . . 84 Function Mode Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84 Fault Clear Button Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84 Temporarily Disable Keypad Motor Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85 Datalink . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85 Message Instruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85 Keypad Actions in Local and Function Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86 Chapter 5 Standard and Configurable I/O Operation Standard I/O Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87 Standard Input Internal Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88 Standard Input Wiring Examples. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88 Configurable I/O Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89 Configured Fault Actions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89 Configurable I/O Internal Wiring Diagram (Output). . . . . . . . . . . . . . . . . . . . . . . . . . 90 Standard Output Wiring Examples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 Standard I/O Wiring Example. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 Chapter 6 Safety Functions Safety Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92 Stop Category Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92 Performance Level and Safety Integrity Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93 Proof Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93 PFD and PFH Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93 Safety Data for Armor PowerFlex Drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94 Safety Data for Integrated STO and Integrated Safety Functions. . . . . . . . . . . . . . 94 Safety Data for Safety Functions with Safety Feedback . . . . . . . . . . . . . . . . . . . . . 95 Safety Reaction Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95 Spurious Trip Rate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96 Contact Information If Safety Failure Occurs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96 Safe Torque Off Function. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96 Description of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96 Stop Category Definition for STO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97 Reset Ownership . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97 Out-of-Box State . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98 Reset to Out-of-box State . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99 Recognize Out-of-box State Using a Message Instruction. . . . . . . . . . . . . . . . . . . . 99 STO Bypass Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 Hardwired Safe Torque Off Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 Hardwired STO Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 Hardwired STO Daisy Chaining Signal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102 Rockwell Automation Publication 35-UM001G-EN-P - September 2024 5 Table of Contents Hardwired STO Fault Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102 Integrated Safety Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104 Integrated Safety Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104 Integrated Safety System Application Requirements. . . . . . . . . . . . . . . . . . . . . . . 105 Drive-based Integrated Safe Stop Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105 Integrated Safe Torque Off Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106 Safe Torque Off Safety Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110 Safe Stop 1 Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111 Safe Brake Control Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116 Safety Feedback . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121 Safety Encoder Diagnostics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122 Digital AqB Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123 Sine/Cosine and Hiperface Diagnostics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123 Controller-based Safe Monitor Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124 Before Adding the Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125 Drive Safety Instruction Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125 Safety Feedback Interface Instruction Operation. . . . . . . . . . . . . . . . . . . . . . . . . . 126 Monitor Safety Status and Faults via a Message Instruction. . . . . . . . . . . . . . . . . . . . . 126 Safety Supervisor State . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126 Safety Core Fault. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127 Safe Torque Off Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127 Safe Stop 1 Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128 Safe Brake Control Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128 SLS, SLP, and SDI Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129 Safety Feedback Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129 Safety Fault Reset. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130 Safety I/O Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130 Safe State. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131 Safety Input Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131 Safety Input Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132 Safety Input Status Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136 Safety Input Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139 Determining Safety Input Alarm Type. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140 Safety Input Alarm Recovery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140 Safety Output Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141 Safety Output Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143 Test Output Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145 Safety Input or Output Fault Recovery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146 Safety I/O Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147 Safety Input Internal Wiring Diagram Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147 Safety Output Internal Wiring Diagram Example. . . . . . . . . . . . . . . . . . . . . . . . . . . 147 Status and Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148 Safety Input Wiring Examples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148 Safety Output Wiring Examples. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149 Replacing an Armor PowerFlex Drive on a Safety Network . . . . . . . . . . . . . . . . . . . . . . 150 Replace an Armor PowerFlex drive in a GuardLogix System . . . . . . . . . . . . . . . . . 150 Configure Only When No Safety Signature Exists . . . . . . . . . . . . . . . . . . . . . . . . . . 151 Configure Always. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151 6 Rockwell Automation Publication 35-UM001G-EN-P - September 2024 Table of Contents Chapter 7 Configure the Armor PowerFlex Install Armor PowerFlex Add-on Profile . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153 Create a Logix Designer Project . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153 Drive Select FactoryTalk Linx Communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154 Add an Armor PowerFlex Drive to the Project . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156 Logix Designer Application Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156 Configure the Device Definition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156 Configure Datalinks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159 View or Generate a Safety Network Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161 Enable Inhibit Module Connection for Quick Start . . . . . . . . . . . . . . . . . . . . . . . . . 162 Quick Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162 Configure Motor Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166 Configure Motor Control Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167 Configure Motor Polarity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169 Configure Slip Droop Compensation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169 Configure Motor Nameplate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170 Configure Motor Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172 Run Autotune . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173 Configure Flying Start. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176 Configure Auto Restart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176 Configure Encoder Feedback . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177 Configure Velocity Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178 Velocity Limits. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179 Preset Velocity, Acceleration Time, Deceleration Time, S-Curve . . . . . . . . . . . . . 180 Output Frequency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182 Jog Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182 Configure Stop Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183 Configure DC Brake. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184 Configure Dynamic Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185 Configure Electromechanical Brake. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186 Configure Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188 Standard Connection Settings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188 Safety Input and Output Connection Settings (safety variants only) . . . . . . . . . . 189 Configure Standard I/O Points. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190 Configure Events. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191 Configure Safety Functions (safety version) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192 Safety Configuration Reset Ownership. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192 Configure Safety Feedback . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192 Configure Scaling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193 Configure Safe Torque Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194 Configure Safe Brake Control (SBC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195 Configure Safe Stop 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196 Configure Test Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198 Configure Safety Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198 Configure Safety Outputs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200 Configure Safety Listen Only Connection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200 Configure Safety Actions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203 Using Automatic Device Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205 Auto-generated Tags . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205 Rockwell Automation Publication 35-UM001G-EN-P - September 2024 7 Table of Contents Chapter 8 Develop Secure Applications CIP Security . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214 Automatic Device Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214 Syslog Event Logging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215 Reset to Out-of-Box for Secure Erase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215 Disable Ethernet Ports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215 Disable the Ethernet Port on the FactoryTalk Linx Configuration Tab. . . . . . . . . 215 Disable the Ethernet Port with a MSG Instruction . . . . . . . . . . . . . . . . . . . . . . . . . . 218 Chapter 9 Diagnostics, Status, and Troubleshooting View Status Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221 System Status Indicator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221 I/O Status Indicators. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221 EtherNet/IP Status Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222 Power Status Indicators. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223 Keypad Status Indicators. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224 Safety Function Status Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225 Monitor Faults, Alarms, and Events. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226 Set Date and Time. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227 Saving Fault History . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228 Exporting Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229 Access Fault, Alarm, and Event Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230 Clearing Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230 Standard Fault. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230 Safety Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232 Condition Monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233 Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233 Temperature Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233 Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234 Chapter 10 Maintenance and Repair Predictive Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235 Remove Power Before Servicing the Armor PowerFlex Drive . . . . . . . . . . . . . . . . . . . . 236 Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236 Test for Hazardous Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237 Fuse Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239 3-phase AC Power and EM Brake Fuse Replacement . . . . . . . . . . . . . . . . . . . . . . . 239 Switched and Unswitched +24V DC Power Fuse Replacement . . . . . . . . . . . . . . . 241 Fan Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242 Bus Capacitor Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242 Appendix A Integrated Safety Instruction Validation Checklist 8 Safe Stop 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243 Safely-limited Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244 Safely-limited Position. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245 Safe Direction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 247 Safe Feedback Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 247 Safe Brake Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 249 Rockwell Automation Publication 35-UM001G-EN-P - September 2024 Table of Contents Appendix B Configure a Message Instruction Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 251 Message Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 251 Example: Read SS1 Fault Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 253 Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 255 Rockwell Automation Publication 35-UM001G-EN-P - September 2024 9 Table of Contents Notes: 10 Rockwell Automation Publication 35-UM001G-EN-P - September 2024 Preface About This Publication This manual describes Armor™ PowerFlex® AC drives with EtherNet/IP® and Armor PowerFlex drives with Integrated Safety via EtherNet/IP. It includes information on installation, configuration, programming, and use. This manual is intended for engineers or technicians that are directly involved in the installation, wiring, programming, operation, and maintenance of the Armor PowerFlex drive. Rockwell Automation recognizes that some of the terms that are currently used in our industry and in this publication are not in alignment with the movement toward inclusive language in technology. We are proactively collaborating with industry peers to find alternatives to such terms and making changes to our products and content. Please excuse the use of such terms in our content while we implement these changes. Summary of Changes This publication contains the following new or updated information. This list includes substantive updates only and is not intended to reflect all changes. Topic Updated Armor PowerFlex images Conventions Page throughout In this manual, we use the term GuardLogix® controller to collectively refer to all of the following safety programmable controllers: GuardLogix, Compact GuardLogix, Armor GuardLogix, and Armor Compact GuardLogix controllers. We use the term Logix controller to collectively refer to all compatible programmable controllers. See Integrated Safety Functions and Compatible Controllers on page 91 for more information. Access Fault Code and CIP Object and Attribute Data Download Firmware, AOP, EDS, and Other Files This manual links to Armor PowerFlex AC Drive Fault Codes Reference Data, publication 35-RD002 and to Armor PowerFlex AC Drive CIP Objects and Attributes Reference Data, publication 35-RD001. Download the spreadsheets from Literature Library. Download firmware, associated files (such as AOP, EDS, and DTM), and access product release notes from the Product Compatibility and Download Center at rok.auto/pcdc. Rockwell Automation Publication 35-UM001G-EN-P - September 2024 11 Preface Terminology This table defines the abbreviations that are used in this manual. Abbreviations and Definitions Abbreviation 1oo2 CAT CL DC DeviceID EN ESD ESPE HFT IEC IGBT ISO MTTF PELV PFD PFH PL PM SELV SIL SSN STR STO Full Term One out of Two Definition Refers to the behavioral design of a dual-channel safety system. Classification of the safety-related parts of a control system in respect of their resistance to faults Category and their subsequent behavior in the fault condition, and which is achieved by the structural arrangement of the parts, fault detection, and/or by their reliability (source ISO 13849). The maximum Safety Integrity Level (SIL) rating that can be claimed for a safety-related electrical Claim Limit control system subsystem in relation to architectural constraints and systematic safety integrity (source IEC 62061). Diagnostic Coverage The ratio of the detected failure rate to the total failure rate. A unique identifier, which is comprised of the module number and Safety Network Number (SNN), to Device ID make sure that duplicate module numbers do not compromise communication between the correct safety devices. European Norm The official European Standard. A system, usually independent of the main control system, which is designed to safely shut down an Emergency Shutdown Systems operating system. An assembly of devices and/or components working together for protective tripping or presencesensing purposes and includes as a minimum: • A sensing device. Electro-sensitive Protective Equipment • Controlling/monitoring devices. • Output signal-switching devices (OSSD). The Hardware Fault Tolerance (HFT) equals n, where n+1 faults could cause the loss of the safety Hardware Fault Tolerance function. An HFT of one means that two faults are required before safety is lost. The International Electrotechnical Commission (IEC) is the organization that prepares and publishes International Electrotechnical Commission international standards for all electrical, electronic, and related technologies. Insulated Gate Bipolar Transistors Typical power switch that is used to control main current. International Organization for Standardization (ISO)is an international standard-setting body that International Organization for Standardization The is composed of representatives from various national standards organizations. Mean Time to Failure The length of time that a device or other product is expected to remain reliable in operation. An electrical system where the voltage cannot exceed ELV under normal conditions, and under singleProtective Extra Low Voltage fault conditions, except earth faults in other circuits. Average Probability of a Dangerous Failure on The average probability of a system to fail to perform its design function on demand. Demand Average Frequency of a Dangerous Failure per The average frequency of a system to have a dangerous failure per hour. hour Performance Level EN ISO 13849-1 safety rating In permanent magnet (PM) motors, magnets mounted on or embedded in the rotor, couple with the Permanent Magnet current-induced internal magnetic fields of the motor generated by electrical input to the stator. A secondary circuit that is designed and protected so that, under normal and single fault conditions, Safety Extra Low Voltage Circuit its voltages do not exceed a safe value. Safety Integrity Level A measure of a products ability to lower the risk that a dangerous failure could occur. Safety Network Number A unique number that identifies a section of a safety network. Spurious Trip Rate That part of the overall failure rate that does not lead to a dangerous undetected failure. The Safe Torque Off (STO) function is used to help prevent unexpected motor rotation during an Safe Torque Off emergency while the drive remains connected to the power supply. When STO is activated, the torque power cannot reach the drive, which stops and helps prevent any motor shaft rotation. Additional Resources These documents contain additional information concerning related products from Rockwell Automation. Resource Armor PowerFlex AC Drives Fault Codes Reference Data, publication 35-RD002 Armor PowerFlex AC Drives CIP Objects and Attributes Reference Data, publication 35-RD001 Description Provides a list of Armor PowerFlex drive fault codes. Provides a list of Armor PowerFlex drive CIP® objects and attributes. Provides information on product specifications, ratings, certifications, system interface, Armor PowerFlex Drives Specifications Technical Data, publication 35-TD001 and wiring diagrams to aid in product selection. Provides basic information on how to install, configure, and program the Armor PowerFlex Armor PowerFlex Motor Controller Product Information, publication 35-PC001 controllers. 12 Rockwell Automation Publication 35-UM001G-EN-P - September 2024 Preface Resource On-Machine Media for Armor PowerFlex, ArmorStart, and ArmorConnect Products Selection Guide, publication 280PWR-SG001 EtherNet/IP Device Level Ring Application Technique, publication ENET-AT007 EtherNet/IP Network Devices User Manual, publication ENET-UM006 Group Installation Listing Requirements for Drives and Contactor-based Motor Controllers White Paper, publication 280-WP001 Armor PowerFlex Fan Replacement Kit Installation Instructions, publication 35-IN008 Armor PowerFlex Electronic Motor Disconnect Whitepaper, publication 35-WP001 PowerFlex AC Drive Performance Specifications per Ecodesign Regulation (EU) 2019/1781 and UK SI 2021 No. 745, publication PFLEX-TD003 Logix5000 Controllers Common Procedures Programming Manual, publication 1756-PM001 Description Provides information on product specifications, ratings, certifications, system interface, wiring diagrams, and dimensions to aid in On-Machine™ media product selection. Describes Device Level Ring (DLR) topologies, configuration considerations, and diagnostic methods. Describes how to configure and use EtherNet/IP devices with a Logix 5000® controller and communicate with various devices on the Ethernet network. Describes the importance of drives and motor controllers being Listed for group installations and how to verify if they have been Listed for group installations. Provides instructions on how to replace the Armor PowerFlex fan. Provides information about motor protection using the electronic motor disconnect. Provides specifications per EU and UK Ecodesign, including efficiency class. Provides access to the Logix 5000 Controllers set of programming manuals. The manuals cover such topics as how to manage project files, organize tags, program logic, test routines, handle faults, and more. Provides information on the programming instructions available to use in Logix Designer application projects. Logix5000 Controllers General Instructions Reference Manual, publication 1756-RM003 GuardLogix Safety Application Instruction Set Reference Manual, publication Provides information on the GuardLogix Safety application instruction set. 1756-RM095 GuardLogix 5570 and Compact GuardLogix 5370 Controller Systems Safety Provides information on safety application requirements for GuardLogix 5570 and Compact Reference Manual, publication 1756-RM099 GuardLogix 5370 controllers in Studio 5000 Logix Designer® applications. GuardLogix 5580 and Compact GuardLogix 5380 Controller Systems Safety Provides information on safety application requirements for GuardLogix 5580 and Compact GuardLogix 5380 controllers in Studio 5000 Logix Designer applications. Reference, publication 1756-RM012 Provides information on how to use standard Guard Logix 5570 controllers. GuardLogix 5570 Controllers User Manual, publication 1756-UM022 ControlLogix 5580 and GuardLogix 5580 Controllers User Manual, publication Provides information on how to use standard ControlLogix® 5580 controllers. 1756-UM543 Compact GuardLogix 5370 Controllers User Manual, publication 1769-UM022 Provides information on how to use Compact GuardLogix 5370 controllers. CompactLogix 5380 and Compact GuardLogix 5380 Controllers User Manual, Provides information on how to use CompactLogix™ 5380 and Compact GuardLogix 5380 controllers. publication 5069-UM001 Wiring and Grounding Guidelines for Pulse-width Modulated (PWM) AC Drives, Provides information to install, protect, wire, and ground pulse-width modulated (PWM) publication DRIVES-IN001 AC drives. Preventive Maintenance of Industrial Control and Drive System Equipment Provides guidelines for maintenance of industrial control and drive system equipment. Technical Data, publication DRIVES-TD001 System Design for Control of Electrical Noise Reference Manual, publication Information, examples, and techniques that are designed to minimize system failures caused by electrical noise. GMC-RM001 Download Safety Automation Builder® software to help simplify machine safety design and validation, and reduce time and costs. Safety Automation Builder and SISTEMA Library The SISTEMA tool, also available for download from the Safety Automation Builder page, automates calculation of the attained Performance Level from the safety-related parts of a machine’s control system to (EN) ISO 13849-1. Describes basic Ethernet concepts, infrastructure components, and infrastructure features. Ethernet Reference Manual publication, ENET-RM002 Provides information on CIP Security™, including which Rockwell Automation products CIP Security with Rockwell Automation Products Application Technique, support CIP Security. publication SECURE-AT001 Provides guidance on how to conduct security assessments, implement Rockwell System Security Design Guidelines Reference Manual publication, Automation® products in a secure system, harden the control system, manage user access, SECURE-RM001 and dispose of equipment. American Standards, Configurations, and Ratings: Introduction to Motor Circuit Design, publication IC-AT001 Industrial Components Preventive Maintenance, Enclosures, and Contact Ratings Specifications, publication IC-TD002 Industrial Automation Wiring and Grounding Guidelines, publication 1770-4.1 Safety Guidelines for the Application, Installation, and Maintenance of Solid-state Control, publication SGI-1.1 Product Certifications website, rok.auto/certifications. Provides an overview of American motor circuit design based on methods that are outlined in the NEC®. Provides a quick reference tool for Allen-Bradley® industrial automation controls and assemblies. Provides general guidelines for installing a Rockwell Automation industrial system. Designed to harmonize with NEMA Standards Publication No. ICS 1.1-1987 and provides general guidelines for the application, installation, and maintenance of solid-state control in the form of individual devices or packaged assemblies incorporating solid-state components. Provides declarations of conformity, certificates, and other certification details. You can view or download publications at rok.auto/literature. Rockwell Automation Publication 35-UM001G-EN-P - September 2024 13 Preface CE and UKCA Conformity CE and UKCA Declarations of Conformity are available online at: rok.auto/certifications. The Armor PowerFlex drive when installed and maintained in accordance with the instructions in this document, is in conformity with the essential requirements of these directives/ regulations: • 2006/42/EC Machinery Directive/2008 No. 1597 Supply of Machinery (Safety) Regulations (MD) • 2014/30/EU EMC Directive/2016 No. 1091 Electromagnetic Compatibility Regulations (EMC) • 2014/35/EU Low Voltage Directive /2016 No. 1101 Electrical Equipment (Safety) Regulations (LV) • 2011/65/EU RoHS Directive/2012 No. 3032 RoHS Regulations (RoHS) • 2009/125/EC Ecodesign Directive/2021 No. 745 Ecodesign for Energy-Related Products Regulations (Eco) The following standards have been applied to demonstrate conformity. Machinery Directive (2006/42/EC)/2008 No. 1597 Supply of Machinery (Safety) Regulations (MD) • • • • • EN ISO 13849-1 Safety of machinery - Safety related parts of control systems - Part 1: General principles for design EN 60204-1 Safety of machinery - Electrical equipment of machines - Part 1: General requirements EN 62061 Safety of machinery - Functional safety of safety-related electrical, electronic, and programmable electronic control systems EN 61800-5-2 Adjustable speed electrical power drive systems - Part 5- 2: Safety requirement - Functional IEC 61508 Part 1…7 Functional safety of electrical/electronic/ programmable electronic safety-related systems EMC Directive (2014/30/EU)/2016 No. 1091 Electromagnetic Compatibility Regulations (EMC) • EN 61800-3 Adjustable speed electric power drive systems - Part 3: EMC requirements and specific test methods LVD Directive (2014/35/EU)/2016 No. 1101 Electrical Equipment (Safety) Regulations (LV) • EN 61800-5 -1 Adjustable speed electrical power drive systems - Part 5-1: Safety requirements – Electrical, thermal and energy (LVD) RoHS Directive (2011/65/EU)/2012 No. 3032 RoHS Regulations (RoHS) • EN 63000 Technical documentation for the assessment of electrical and electronic products with respect to the restriction of hazardous substances Ecodesign Directive (2019/1781/EU)/2021 No. 745 Ecodesign for Energy-Related Products Regulations (Eco) 14 Rockwell Automation Publication 35-UM001G-EN-P - September 2024 Chapter 1 Armor PowerFlex Variable Frequency Drives Overview Description The Armor™ PowerFlex® unit is a variable frequency drive (VFD) and is suited for variable frequency applications where more precise motor control is needed. The Armor PowerFlex drives are available in integrated safety (Bulletin 35S) and standard (Bulletin 35E) versions. All Armor PowerFlex drives feature an embedded dual-port EtherNet/IP™ switch, which supports star, linear, and DLR topologies. The Armor PowerFlex drive provides an IP54/66, UL Type 4/12, and NEMA 4/12 enclosure design, which is suitable for water wash down environments, when appropriate cables are attached or sealing caps are in place. For details, see Armor PowerFlex AC Drives Specifications, publication 35-TD001 and the On-Machine Media for Armor PowerFlex, ArmorStart, and ArmorConnect Products Selection Guide, publication 280PWR-SG001. IMPORTANT To ensure that Armor PowerFlex system, which includes cables and sealing caps, meet the application requirement, see the Armor PowerFlex Enclosure Ratings when used with Cable Assemblies and Sealing Caps table located in the On-Machine Media for Armor PowerFlex, ArmorStart, and ArmorConnect Products Selection Guide, publication 280PWR-SG001. IMPORTANT The Armor PowerFlex drive ships with a screw-in cap which is required to be installed when the power OUT connection is not in use. (This scenario could apply when daisy chaining is not in use or when the drive is the last unit in the daisy chain). When installed, this screw-in cap provides an IP54 rating to the power OUT connection. If a greater IP rating is required, for example IP66, appropriately rated sealing caps are required to be installed. For selection information, see Accessories in the On-Machine Media for Armor PowerFlex, ArmorStart, and ArmorConnect Products Selection Guide, publication 280PWR-SG001. Fault diagnostic capabilities, including status indicators, are built in to the Armor PowerFlex drive to help you pinpoint a problem for easy troubleshooting and quick restarting. Input and Outputs All Armor PowerFlex drives include four standard inputs and two standard configurable I/Os. The Armor PowerFlex safety drive includes: two test outputs, four safety inputs, and one bipolar safety output. Table 1 - Product Overview Type Armor PowerFlex with integrated safety on EtherNet/IP network Armor PowerFlex on EtherNet/IP network On-board Safety Inputs and Outputs(1) 1 bipolar safety output 4 inputs 4 safety inputs 2 configurable I/Os — Bulletin Inputs and Outputs 35S 35E (1) When Armor PowerFlex with integrated safety is configured for hardwired Safe Torque Off (STO), one of the input channel pairs is used for STO and the remaining safety I/O is not available. For details, see Hardwired Safe Torque Off Function on page 100. Rockwell Automation Publication 35-UM001G-EN-P - September 2024 15 Chapter 1 Armor PowerFlex Variable Frequency Drives Overview Frame Size The Armor PowerFlex drive is available in Frame sizes A and B. Table 2 - Frame Sizes Frame Output Current Size Rating A 1 Hp (0.75 kW) 2 Hp (1.5 kW) 4.0 A 3 Hp (2.2 kW) 6.0 A 5 Hp (3.7 kW) 7.5 Hp (5.6 kW) 10.5 A 10 Hp (7.5 kW) 17 A B Approximate Dimensions Width Depth Diagram (W), (D), max. max. Input Voltage 2.3 A H W 16.0 in. 5.67 in. 8.0 in. (40.6 cm) (14.4 cm) (20.3 cm) D 380…480V AC Height (H), max. H W 13 A 380…480V AC D 18.3 in. 7.2 in. 8.0 in. (46.5 cm) (18.2 cm) (20.3 cm) For additional specifications see Armor PowerFlex AC Drives Specifications Technical Data, publication 35-TD001. We recommend that the drive rating should be no more than two times the motor rating. Example: For a 1 Hp drive, the motor should be 0.5 Hp or larger. Safety Functions The Armor PowerFlex safety version (35S) is capable of hard-wired and integrated safety. In hardwired mode, Safe Torque Off (STO) can be used. Integrated safety supports STO, integrated drive-based Safe Stop functions and integrated controller-based Safe Monitor functions. See Chapter 6, for details. 16 Rockwell Automation Publication 35-UM001G-EN-P - September 2024 Chapter 1 Armor PowerFlex Variable Frequency Drives Overview Location of Features Figure 1 - Bulletin 35E Armor PowerFlex Standard VFD (Frame Size A) With external power supply With internal power supply Jog and Direction Buttons Status Indicators Local Disconnect Jog and Direction Buttons Encoder Standard I/Os Standard I/Os Configurable I/O Configurable I/O Gigabit Ethernet Port Gigabit Ethernet Port Status Indicators 24V DC Auxiliary Power IN Dynamic Brake Connection Dynamic Brake Connection 3-phase Power IN Motor Connection OR Motor with Optional Electromechanical Brake Connection Motor Connection OR Motor with Optional Electromechanical Brake Connection 3-phase Power OUT Local Disconnect Encoder 24V DC Auxiliary Power OUT 3-phase Power OUT 3-phase Power IN Figure 2 - Bulletin 35S Armor PowerFlex with Integrated Safety VFD (Frame Size A) With internal power supply Status Indicators Safety I/Os Jog and Direction Encoder Buttons With external power supply Status Indicators Safety I/Os Jog and Direction Encoder Buttons Local Disconnect Standard I/Os Standard I/Os Configurable I/O Configurable I/O Gigabit Ethernet Port Gigabit Ethernet Port 24V DC Auxiliary Power IN Dynamic Brake Connection Dynamic Brake Connection 3-phase Power IN Motor Connection OR Motor with Optional Electromechanical Brake Connection 3-phase Power OUT Local Disconnect 24V DC Auxiliary Power OUT Motor Connection OR Motor with Optional Electromechanical Brake Connection Rockwell Automation Publication 35-UM001G-EN-P - September 2024 3-phase Power OUT 3-phase Power IN 17 Chapter 1 Armor PowerFlex Variable Frequency Drives Overview Figure 3 - Bulletin 35E Armor PowerFlex Standard VFD (Frame Size B) With external power supply With internal power supply Jog and Direction Buttons Status Indicators Local Disconnect Encoder Status Indicators Encoder Jog and Direction Buttons Standard I/Os Standard I/Os Configurable I/O Configurable I/O Gigabit Ethernet Port Gigabit Ethernet Port 24V DC Auxiliary Power IN Dynamic Brake Connection Dynamic Brake Connection Local Disconnect 24V DC Auxiliary Power OUT 3-phase Power OUT Motor with 3-phase Power IN Electromechanical Brake Connection 3-phase Power IN Motor with 3-phase Power OUT Electromechanical Brake Connection Figure 4 - Bulletin 35S Armor PowerFlex with Integrated Safety VFD (Frame Size B) With internal power supply Status Indicators Safety I/Os Jog and Direction Encoder Buttons With external power supply Status Indicators Local Disconnect Jog and Direction Buttons Standard I/Os Standard I/Os Configurable I/O Configurable I/O Gigabit Ethernet Port Gigabit Ethernet Port Safety I/Os Encoder 24V DC Auxiliary Power IN Dynamic Brake Connection Dynamic Brake Connection 3-phase Power IN Motor with Electromechanical Brake Connection 18 3-phase Power OUT Local Disconnect 24V DC Auxiliary Power OUT Motor with Electromechanical Brake Connection Rockwell Automation Publication 35-UM001G-EN-P - September 2024 3-phase Power OUT 3-phase Power IN Chapter 1 Armor PowerFlex Variable Frequency Drives Overview Catalog Number Explanation Examples that are given in this section are not intended to be used for product selection. Not all combinations produce a valid catalog number. Use ProposalWorks™ software to configure the Armor PowerFlex Drive. ProposalWorks software is available from rok.auto/systemtools. Catalog Number Explanation for Bulletin 35 Armor PowerFlex Drives 35 a Code 35 a Bulletin Number Description Armor PowerFlex Drive Code S b b Type Description S Integrated Safety E Standard with EtherNet/IP - 6 c D d 1 e - L f 1 g 1 h 1 i Code c Enclosure Type Description Code d Line Voltage Description 6 IP54/66, NEMA Type 1/4/12(1) D 480Y/277V AC, 50/60 Hz (1) See the On-Machine Media for Armor PowerFlex, ArmorStart, and ArmorConnect Products Selection Guide, publication 280PWR-SG00, for specific enclosure ratings based on cable selection. e Motor Power Output Rating(1) Code 1 2 3 4 5 6 Description Frame A: 1 Hp, 0.75 kW, 2.3 A Frame A: 2 Hp, 1.5 kW, 4.0 A Frame A: 3 Hp, 2.2 kW, 6.0 A Frame B: 5 Hp, 3.7 kW, 10.5 A Frame B: 7.5 Hp, 5.6 kW, 13 A Frame B: 10 Hp, 7.5 kW, 17 A f g h 24V DC Auxiliary Power Source Power-in Gland(2) EM Brake(3) Code L P Description External Internal Code 0 1 2 Description Cord/conduit Round Quick Connect Square Quick Connect Code 0 1 i Description None Included EMI Filter Code 1 Description Included (1) We recommend that the drive rating should be no more than two times the motor rating. For example: For a 1 Hp drive, the motor should be 0.5 Hp or larger. (2) You must select Cord/Conduit or Round Quick Connect power-in gland to qualify for UL Listing. A UL type 4/12 grommet is required for a Cord/Conduit Power-in Gland, in order to achieve a UL type 4/12 rating for a frame size A drive. (3) If you choose a drive without an EM brake (Code 0), then a 4-pin motor cable is required. If you choose a drive with an EM brake (Code 1), then a 7-pin motor cable is required. Example: Cat. No. 35S-6D3-P101 requires a 4-pin cable (Cat. No. 280-PWRM29-Mxx or 284-PWRM29-Mxx). Cat. No. 35S-6D3-P111 requires a 7-pin cable (Cat. No. 357-PWRM29-Mxx). For details, see the On-Machine Media for Armor PowerFlex, ArmorStart, and ArmorConnect Products Selection Guide, publication 280PWR-SG001. The EM Brake is standard (included) for Frame B sizes (5, 7.5, and 10 Hp). Required Software Table 3 lists the software that is required to operate Armor PowerFlex drives. Table 3 - Armor PowerFlex Drives Required Software Network Software(1) Version FactoryTalk® Linx(2) 6.20 or later Studio 5000® EtherNet/IP Add-on Profile BOOTP/DHCP Utility Programmable Controller Armor PowerFlex GuardLogix and Compact GuardLogix controllers (see 35S and 35E page 91 for the listing of compatible controllers) versions Armor PowerFlex ControlLogix and CompactLogix controllers (see 35E version page 91 for the listing of compatible controllers) 32.xx…34.xx and 36.xx or later not compatible with 35.xx Download the most current version from the Product Compatibility and Download Center at rok.auto/pcdc Version 2.3 or later (BOOTP is not supported.) Version 32.xx…34.xx and 36.xx or later not compatible with 35.xx 32.xx…34.xx and 36.xx or later not compatible with 35.xx (1) We recommend using a Windows® 10 operating system or higher, to achieve full software functionality. (2) The RSLinx® application is not supported. Studio 5000 Logix Designer® application is the single software that is used for setup and commissioning. It’s accomplished through the installation and use of an Add-on Profile (AOP) downloaded from Product Compatibility and Download Center (PCDC). See page 11 for more information. Rockwell Automation Publication 35-UM001G-EN-P - September 2024 19 Chapter 1 Armor PowerFlex Variable Frequency Drives Overview Motor Control Armor PowerFlex drives provide you with selectable choices for accurate motor control. For induction motors, the Control Axis leverages the IEEE recommended phase-neutral equivalent circuit motor model based on "Wye" configuration. Reactance values, X, are related to their corresponding Inductance values, L, by X = wL, where w is the rated frequency of the motor. The prime notation, for example, X2', R2', indicates that the actual rotor component values X2, and R2 are referenced to the stator side of the stator-to-rotor winding ratio. Figure 5 - IEEE per Phase Motor Model Table 4 - IEEE Phase Motor Model Diagram Designations I1 Stator current [Amps] I2 Rotor current [Amps] R1 Stator circuit resistance [Ohms] R2 Rotor circuit resistance [Ohms] X1 Stator leakage reactance [Ohms] X2 Rotor circuit reactance [Ohms] Iw Magnetizing current [Amps] Xw Magnetizing reactance [Ohms] V1 Applied stator voltage [Volts] Control Modes Velocity control is accomplished via three options for control mode: • Volts/Hertz (V/Hz) • Sensorless Vector (SVC) and Sensorless Vector (SVC) Economizer • Velocity Vector (VVC) Volts/Hertz Volts/Hz (V/Hz) control is a simple, low-cost method for controlling variable frequency drives (VFDs), and is generally regarded as the most common VFD control scheme. It’s suitable for both constant torque and variable torque applications and can provide up to 150% of the rated torque at zero speed for startup and peak loads. The magnetic field strength is proportional to the ratio of voltage (V) to frequency (Hz), or V/Hz. The VFD controls the motor speed by varying the frequency of the applied voltage, according to the synchronous speed equation. Operation in this mode, creates a fixed relationship between output voltage and output frequency. Voltage is applied to the motor, which is based on the operating frequency command at a fixed volts/Hertz ratio. The ratio is calculated from the motor nameplate data. Sensorless Vector Sensorless vector control (SVC) provides better torque production and a wider speed range than V/Hz. However, it may not be appropriate when more than one motor is connected to the same drive. 20 Rockwell Automation Publication 35-UM001G-EN-P - September 2024 Chapter 1 Armor PowerFlex Variable Frequency Drives Overview SVC does not have an external sensor to obtain feedback from a motor. SVC mode monitors the voltage and current of the motor via the already-connected power leads, and then mathematically determines the motor speed with optimum accuracy. This is a simpler and less costly solution than installing and connecting an encoder. While not as good as a dedicated sensor, SVC provides sufficient feedback in most applications to enable pseudo closed-loop operation. SVC uses a V/Hz core that is enhanced by current resolution, a slip estimator, a highperformance current limiter, and the vector algorithms. The algorithms operate on the knowledge that motor current is the vector sum of the torque and flux producing components. Values can be entered to identify the motor values or an autotune routine can be run to identify the motor values (see Run Autotune on page 173). For improved SVC performance, we recommend that an autotune is performed with the motor connected. Sensorless Vector Economizer SVC Economizer mode consists of the sensorless vector control with an additional energy savings function. For details, see Configure Motor Control Mode on page 167. Velocity Vector In Velocity Vector Control (VVC), a high bandwidth regulator that separates and controls the components of stator current, replaces the volts/hertz core used in V/Hz and SVC control modes. The high bandwidth characteristics of this control help eliminate nuisance trips due to shock-loads and will continuously adapt to changes in the motor and load characteristics. A separate adaptive controller uses information gained during auto tuning; actual reference information and motor feedback information, to give independent torque and flux control. This allows continuous regulation of the motor speed and improved overall control. For the Armor PowerFlex drive, this mode should be operated with feedback to provide the fastest response to load changes. A rotate tune must be done in order to provide the optimal motor velocity control using vector mode (see Run Autotune on page 173). Velocity Control Velocity control refers to controlling the speed of a connected motor. Acceleration and deceleration times can be specified, which indicate the time it should take the velocity to go from zero to the configured maximum velocity (or vice versa). From these times, actual acceleration/deceleration values (rates) can be calculated and the motor output controlled to meet these desired values. Example: If Acceleration Time is 10 s, it means that the motor should go from a standstill to maximum velocity in 10 s. Maximum velocity can be lower or higher than rated speed. Velocity control also allows the rate of change of acceleration and deceleration (also known as "jerk") to be adjusted. This control function is known as S-Curve. By enabling/configuring the S-Curve function, the transition between velocities can be made smoother by not immediately applying or removing the desired acceleration/deceleration rate. Rockwell Automation Publication 35-UM001G-EN-P - September 2024 21 Chapter 1 Armor PowerFlex Variable Frequency Drives Overview When S Curve is enabled, it adds time to the overall acceleration by a percentage of the programmed acceleration time. This is shown in the curve in Figure 6 which represents 0%, 25%, 50%, and 100% S Curve. Note that half of the “S” is added to the beginning and half is added to the end of the ramp. Figure 6 - S Curve Example 70.0 60.0 0% 25% 50% 2.0 2.5 3.0 100% Hz 50.0 40.0 30.0 20.0 10.0 0.0 0.0 0.5 1.0 1.5 3.5 4.0 Seconds Flying Start The flying start feature lets you start a motor that is already in motion. Flying start is used to start a rotating motor, as quick as possible, and resume normal operation with a minimal impact on load or speed. When a drive is started in its normal mode, it initially applies a frequency of 0 Hz and ramps to the desired frequency. If the drive is started in this mode with the motor already spinning, large currents will be generated. An overcurrent trip may result if the current limiter cannot react quickly enough. The likelihood of an overcurrent trip is further increased if there is a residual electro-magnetic flux (back EMF) on the spinning motor when the drive starts. In addition, larger mechanical stress is placed on the application. In Flying Start mode, the drive’s response to a start command is to synchronize with the motors speed (frequency and phase) and voltage. The motor will then accelerate to the desired frequency. This process helps prevent an overcurrent trip and significantly reduces the time for the motor to reach its desired frequency. Since the drive synchronizes with the motor at its rotating speed and ramps to the proper speed, little or no mechanical stress is present. With flying start enabled, the drive may cause the motor shaft to slightly rotate forward and/or reverse, when the drive is started in a condition where the motor is not rotating. This motion may occur because the drive performs a sweep of the motor to find its current speed. This sweep produces a small amount of EMF which in turn causes the motor to move. A generic application example for flying start, would be a high inertia load where the rotating load is coasting to a stop and the process requires a re-start of the drive before the rotating load/motor is at rest. Depending on the system design, even with flying start enabled, some applications may require additional hardware to control regenerative energy and prevent an overcurrent or overvoltage fault. ATTENTION: When flying start is enabled and the motor is starting from zero speed, the motor shaft can turn forward or reverse while the algorithm attempts to detect current speed. When flying start is disabled and the drive receives a start command while the motor is in motion, the drive performs a ramp from zero speed (no output frequency) to the commanded speed. Performing this ramp from zero on a running motor can cause an overcurrent condition which may result in damage to the motor or load. Motor Thermal Overload Motor thermal overload protection helps to prevent overheating and possible damage to the connected motor. When the drive detects that the motor is too hot, a thermal overload condition is declared. Power to the motor is removed to allow the motor to cool and the overload condition to clear. When the overload condition is cleared, the motor can be restarted. You can define the behavior of the motor thermal overload feature (erase thermal 22 Rockwell Automation Publication 35-UM001G-EN-P - September 2024 Chapter 1 Armor PowerFlex Variable Frequency Drives Overview memory or allow cool down) when the device powers up. See Configure Motor Protection on page 172. A motor thermal model calculates thermal capacity utilization to estimate the actual heating of the connected motor based on: • Configured motor overload current, which is the level at which the motor is considered to be in an overload condition • Actual product output current (all three phases are measured) • Time over which the output current is delivered The protection feature lets the motor operate at a power level above its overload rating for short periods of time while starting or accelerating to help prevent faults from occurring. When excessive current flows through the motor circuit, there is increased motor temperature sensed which will result in a Drive fault after a specified delay, defined as Class 10. This overheating generally occurs when the motor is overloaded, when a bearing seizes up, when something locks the motor shaft and prevents it from turning, or when the motor simply fails to start properly. A failure to start may be caused by faulty start windings in the motor. See Armor PowerFlex AC Drives Specifications, publication 35-TD001, for overload trip curves specifications. Fault Auto Reset The fault auto reset and run (auto restart) feature lets certain faults be cleared and the product be commanded back into the running state. The Auto Restart feature provides the ability for the drive to automatically perform a fault reset followed by a start attempt without user or application intervention. This allows remote or “unattended” operation. Only certain faults are allowed to be reset. Certain faults that indicate possible drive component malfunction are not resettable. Caution should be used when enabling this feature, since the drive will attempt to issue its own start command based on user selected programming. List of resettable faults: • Inverter - Ground Fault (event code 0x04250002) • Motor Thermal Overload - Overload, Hard (event code 0x04320001) • Load Monitor - Above Level (Shear Pin) (event code 0x04340001) • Load Monitor - Below Level (Load Loss) (event code 0x04340002) • Temperature Sensor - Overtemperature, Hard (event code 0x04230002) IMPORTANT Safe Torque Off and Safe Monitor Functions Multiple simultaneous faults of any type will prevent a restart. The hardwired and integrated safety features are available on the Armor PowerFlex safety drive (35S). Hardwired Safe Torque Off When the Armor PowerFlex safety drive is in its out-of-box state, it operates in hardwired Safe Torque Off (STO) mode. The STO function is controlled by either dual channel safety input; either safety input 0 (SI0) and safety input 1 (SI1), or safety input 2 (SI2) and safety input 3 (SI3). Rockwell Automation Publication 35-UM001G-EN-P - September 2024 23 Chapter 1 Armor PowerFlex Variable Frequency Drives Overview IMPORTANT The Armor PowerFlex safety drive (35S) includes functional safety. If during the initial out-of-box setup a local jog is required, install the red (M12) safety bypass plug onto one of the two safety inputs. This plug is used to enable torque in the out-of-box hardwired mode, during setup. After a safety connection is made with the safety drive, a reset ownership must be performed to enter the out-of-box, hardwired state again. For details, see STO Bypass Operation on page 100. In hardwired mode, only one pair of inputs can be used to control the STO function. If pulse testing of the hardwired safety device is needed per the risk assessment, SI0 and SI1 should be used with test output 0 and test output 1, to perform the pulse testing operation. If pulse testing is not required, SI2 and SI3 should be used without the test outputs connected. If SI0 and SI1 are used without the test outputs connected, STO faults will occur. See Hardwired Safe Torque Off Function on page 100 for details. IMPORTANT In hardwired safety mode, only one of the two safety input connectors can be used. Connecting a cable and safety device to both safety inputs’ connectors, in hardwired safety mode, will cause an STO Both Pairs Used fault. See section Hardwired STO Operation For information on resetting this fault, see Hardwired STO Operation on page 100. Torque is permitted when one input pair on one of the two safety input connectors is energized and disabled when either input is de-energized. Choose the desired safety input connector for hardwired STO mode. See Hardwired Safe Torque Off Function on page 100 for details. Integrated Safety Functions When the Armor PowerFlex is applied with a suitable safety programmable controller, additional functionality is available. This functionality includes network safety functions such as STO, timed SS1, SBC, and Safety I/O. When adding a suitable safety encoder to the Armor PowerFlex drive, it can support additional safe speed monitoring functions, such as SLS, SLP, SDI, and SS1 ramp. In addition to safety I/O features, the drive supports these functions: integrated STO, timed SS1, Safe Brake control (SBC), and monitored SS1 when a safety encoder is used. See Chapter 6 for details on integrated safety I/O and safety functions. Standard Encoder Operation and Diagnostics The Armor PowerFlex drive has a feedback interface that allows an external feedback device (encoder) to be connected to the product. An encoder can provide more accurate velocity control by providing an indication of the actual speed of the motor/load. Supported standard encoder types: • Digital Incremental, Single Channel, Single Ended • Digital Incremental, Single Channel, Differential • Digital Incremental, Dual Channel, Single Ended • Digital Incremental, Dual Channel, Differential The encoder signals are connected in parallel for both safety and standard drive control. Standard control can use single-ended encoder signals, but differential signals are required for safety functions. The standard and safety feedback must be configured separately. If the feedback device uses safe speed monitor functions, additional diagnostics and configuration values must be considered. See Safety Feedback Interface Instruction Operation on page 126 for more information on the controller-based safety encoder support and diagnostics. See Configure Encoder Feedback on page 177 for information on how to configure the standard and safety encoders. The Armor PowerFlex can supply either 5V or 12V to the encoder, through the encoder output. The encoder supply voltage switch must be set to the proper supply voltage (5V or 12V) for your 24 Rockwell Automation Publication 35-UM001G-EN-P - September 2024 Chapter 1 Armor PowerFlex Variable Frequency Drives Overview connected encoder. The encoder supply voltage switch is on the I/O board, next to the IP address switches (see Figure 7). See Remove Front Logic Cover on page 70 for information on how to gain access to the I/O board. Figure 7 - Encoder Supply Voltage Switch FE BYPASS The safety feedback configuration allows for the voltage supply to be monitored, see Encoder Voltage Monitoring on page 122 for more details. IMPORTANT For fault-free operation of the encoder, the cable shield of the connecting cable must be grounded on both sides (encoder and control) using large area connections. On the encoder side, this is typically done in the plug connector or via the connecting cable. IMPORTANT For proper operation of the Armor PowerFlex drive, the maximum total encoder cable length is 20 m (65.6 ft). Supported Standard Encoder Diagnostics: • Wire Error Detection • Velocity Comparison The standard encoder diagnostics support basic wire error checking and velocity comparison. The standard encoder diagnostics check for wiring errors and reports them to the user. The diagnostics detect when 1 of the 4 encoder signals is open, shorted to ground, or shorted to encoder power. The velocity comparison diagnostic detects when the measured velocity from the encoder is outside of the expected velocity value. For more information, see Configure Encoder Feedback on page 177. Group Motor Application IMPORTANT The Armor PowerFlex drives and their mating cable assemblies can be applied using NFPA 70 (NEC), NFPA 79, and specific local electrical code as required. The Armor PowerFlex drive integrates the motor branch short circuit and ground fault protection devices. Therefore, no additional motor control branch circuit protection is required. Multiple Armor PowerFlex drives can be applied in a group application if you follow the local electrical codes for the protection of the feeder conductors using recommended Branch Circuit Protection device. Local Disconnect The Armor PowerFlex drive has a local, at-motor disconnect switch which is positioned on the front of the unit. The local disconnect meets NFPA compliances, for details, see the Armor PowerFlex AC Drives Specifications Technical Data, publication 35-TD001. Rockwell Automation Publication 35-UM001G-EN-P - September 2024 25 Chapter 1 Armor PowerFlex Variable Frequency Drives Overview The local disconnect removes power from the motor terminals and digital outputs when in the Off position. A lock can be applied to the local disconnect when in the Off position. For additional information, see Local Disconnect Behavior on page 66. After the outside cover is removed, the local disconnect provides a maintenance engineer or technician, access to finger safe test points. These test points are intended to be used in conjunction with lock-out tag-out procedures. The test points allow you to test and verify that hazardous power supplied to the Armor PowerFlex, has reached a safe state and that any accumulated or stored energy has dissipated or discharged to a safe state, as required by local lock-out tag-out standards. For details, see Remove Power Before Servicing the Armor PowerFlex Drive on page 236. If a motor over-current fault should occur, the integrated branch protection may trip. This may cause the drive to fault if the bus voltage falls below minimum threshold. If a fault occurs, the disconnect switch (On/Off) position will not change state. For diagnostic help and trouble shooting, see System Status Indicator on page 221. EMI Filter The EMI filter is required to be CE compliant. The filter must only be used in installations with solidly grounded Wye AC supply distribution and must be bonded to the power distribution ground. The shielded motor cable is ordered separately. Use the Rockwell Automation® power media and cable assemblies that are specified by the selection guide or instructions for the controller, to comply with the UL Listing of the controller. See the Armor PowerFlex AC Drives Specifications Technical Data, publication 35-TD001 and the On-Machine Media for Armor PowerFlex, ArmorStart, and ArmorConnect Products Selection Guide, publication, 280PWR-SG001, for available catalog numbers. Dynamic Brake Resistor Dynamic braking (DB) allows excess electrical energy to be dissipated as thermal energy by directing it through a large resistor. When the dynamic braking feature is enabled, the brake resistor is activated (current is allowed to flow through it) when the bus voltage exceeds a user-defined threshold. This is primarily useful when stopping, allowing a faster stop without causing a DC bus overvoltage. Typically, AC drives do not offer protection for externally mounted dynamic brake resistors. A risk of fire exists if external braking resistors are not protected from drive component failure, for example, failure of the brake IGBT. In this case, external resistor packages must be protected from over-temperature condition using a protective circuit, or equivalent, as the example shown. The Armor PowerFlex frame size A (1…3 Hp) and frame size B(a) (5…10 Hp) have the internal ability to detect a thermal event on the dynamic brake resistor and shut down the Electronic Motor Disconnect which eliminates the need for the upstream control devices. See Electronic Motor Disconnect on page 67, for more information. (a) Frame size B must have firmware revision 2.002 or higher. 26 Rockwell Automation Publication 35-UM001G-EN-P - September 2024 Chapter 1 Armor PowerFlex Variable Frequency Drives Overview The dynamic brake resistor kit is available for light-duty applications (mountable, does not take extra space) or standard duty applications (larger footprint, with more capability). The dynamic brake resistor kit can be factory-ordered separately. See the Armor PowerFlex AC Drive Specifications Technical Data, publication 35-TD001, for available catalog numbers. IMPORTANT Frame size A drives (1…3 Hp) support the dynamic brake function. Do not use any type of brake resistor with frame size B drives (5…10 Hp) with firmware revision 2.001. You must update the firmware to revision 2.002 or higher, to enable an enhanced level of dynamic brake resistor protection. IMPORTANT We recommend that you apply only light-duty or standard-duty dynamic braking resistors, based on your application needs. If you require a deviation from the Rockwell Automation recommended resistors, it is your responsibility to ensure it is suitable to be used with the Armor PowerFlex drive and will meet the application’s needs. As a precaution, you should review these changes with your UL representative or Authority Having Jurisdiction (AHJ). The dynamic brake connector is provided standard with the Armor PowerFlex drive. Power Input Gland The Armor PowerFlex drive offers several methods to connect 3-phase power to the unit. You can select one of the three offered connectivity options via the catalog number configuration. Conduit/cord allows you to apply conduit or cord to manually terminate each conductor. Factory-installed receptacles can be selected to provide connectivity to three-phase quickconnections. You can select the round M35 ArmorConnect® quick-connect power media, or you can select the square quick-connect that offers connectivity to DESINA Q4/2 connectors, such as HARTING® power cable assembly solutions. For selection information, see the OnMachine Media for Armor PowerFlex, ArmorStart, and ArmorConnect Products Selection Guide, publication, 280PWR-SG001. Factory-installed Options You must select factory-installed options and add them to the catalog number selection before ordering. Options are not modular and you cannot install them on site. Internal Power Supply When you select your Armor PowerFlex drive catalog number, you can choose for it to be configured with an internal 24V DC auxiliary power supply (50 W) or you can choose to have an external power supply. Your power supply choice is made by catalog number selection and cannot be changed in the field. The internal power supply provides all control and I/O power and is sourced from the incoming three-phase power. This eliminates the need to run separate control power to each unit, reducing installation time and cost. The internal power supply (IPS) connects to the line side of the local disconnect. This means that when the local disconnect is Off, the IPS will continue to provide 24V DC to the Armor PowerFlex. Only when the machine level (main) disconnect is Off, removing all three-phase power, does the IPS shutdown and the Armor PowerFlex drive turns Off. The Armor PowerFlex drive can source a Class 2 circuit according to the NEC 725.60 standard, which covers unswitched power (for sensors) and/or switched power (for actuators). For more information, see the Armor PowerFlex AC Drive Specifications Technical Data, publication 35-TD001. Rockwell Automation Publication 35-UM001G-EN-P - September 2024 27 Chapter 1 Armor PowerFlex Variable Frequency Drives Overview Electromechanical Brake The Armor PowerFlex Drive supports an electromechanical brake (EMB or EM brake) function. For frame size A, the EM Brake Control is optional, but for frame size B, this functionality is standard. Internally controlled (On/Off) mechanical contacts apply source (line) voltage to the external motor mechanical brake solenoid when it is demanded. This releases the motor brake to allow motion. Both Automatic and Manual brake control are available with the Armor PowerFlex drive. For details, see Configure Electromechanical Brake on page 186. IMPORTANT In Automatic mode, if the EM Brake is released and later the drive were to fault, the EM brake will revert to “engaged” status. But in manual or controller tag mode, if the drive were to fault, you continue to have control over the EM Brake. The EM Brake state will not change until you manually change it. A customer-accessible, 3 A fuse is provided to help protect the brake cable from over-current. The brake and motor conductors are integrated into a single cable assembly and ordered separately. Use the Rockwell Automation power media and cable assemblies that are specified in the selection guide or instructions for the drive, to comply with the UL Listing of the drive. See the On-Machine Media for Armor PowerFlex, ArmorStart, and ArmorConnect Products Selection Guide, publication, 280PWR-SG001. The EM brake current is a calculated AC RMS value based on peak averages, and not a “true RMS” value. If the brake output is nonsinusoidal (such as a half wave rectifier), the calculated RMS current will be incorrect and potentially cause a fault. The EM brake fault can be disabled if the brake being used has a low current draw. 28 IMPORTANT For proper operation, the minimum EM brake current required is 100 mA. Current draw less than 70 mA rms will cause an undercurrent fault, that could be due to the EM brake not being connected or a broken wire. IMPORTANT The EM brake feedback current must be sinusoidal or an EM brake current fault may occur. Rockwell Automation Publication 35-UM001G-EN-P - September 2024 Chapter 1 Typical Configurations Armor PowerFlex Variable Frequency Drives Overview Armor PowerFlex drives can be configured for standard or safety applications. Standard Configuration The Armor PowerFlex standard drive (35E) is normally applied in systems where integrated safety functions are not required (see Figure 8). For more complex systems or systems with higher-end safety requirements, you should consider using the Armor PowerFlex integrated safety drive (35S). Figure 8 - Standard Drives Configuration Programmable Controller Ethernet cable Ethernet Managed Switch EtherNet/IP (supports DLR) Note: Adapter cables are available to connect the Armor PowerFlex X-code Ethernet port to a D-code 10/100 Ethernet port. For cable selection, see the On-Machine Media for Armor PowerFlex, ArmorStart, and ArmorConnect Products Selection Guide, publication 280PWR-SG001. Ethernet cable Main Power Circuit Protection Armor PowerFlex Drive (35E) Frame Size B 120V AC 24V DC Power Supply Armor PowerFlex Drive (35E) Frame Size A Input - 0,1 Input - 2,3 Input - 0,1 Input - 2,3 Configurable I/O - 0,1 Configurable I/O - 0,1 24V DC Ethernet cable Encoder 3-phase Power Armor PowerFlex 35E Drive with NFPA 70 Emergency Stop The Armor PowerFlex drive internally integrates motor branch short circuit and ground fault protection devices. No additional motor control branch circuit protection is required and the drive can be installed in a group application. For upstream group protection, it is possible to use one branch circuit protection device. Though not related to NFPA 70 Emergency Stop, the following example will show the calculations for sizing the branch circuit protection device. Many applications require the use of an Emergency Stop device using NFPA 79 regulations. The following example achieves NPFA 79 status by using a method of relay-controlled removal of power from the Armor PowerFlex 35E standard drive, to the motors. The wiring example demonstrates how to achieve a Category 0, NPFA 70 Emergency Stop status, in which the motor will coast to stop, based on friction and losses. This example can be used on any nonsafety drive, as a means to remove power to the motors and achieve a Category 0, stop. Rockwell Automation Publication 35-UM001G-EN-P - September 2024 29 Chapter 1 Armor PowerFlex Variable Frequency Drives Overview Hardware used for the example: • (3) Armor PowerFlex 35E-6D1-P001 • (3) AC motors 2.3 FLA • Power and motor cables. To comply with UL Listing of drive, use Rockwell Automation cable assemblies see publication 280PWR-SG001) • Safety Relay; 440R-D2252 • Bulletin 100S safety rated contactors; 100S-C09EJ23C MCS 100S-C, 9amp, 24V DC-2 • Bussmann Fuses; LPJ-9SP • 800F E-Stop Push Button; 800FM-G611MX11 Calculation of fuse and contactor sizing: 2.3 A Motor FLA x 3 x 1.25 = 8.625 A. A 9 A rating fuse and contactor was chosen. In this example, the fuse is sized to NEC code or the sum of motor minimum: FLA x 1.25. IMPORTANT Follow local code for sizing based on your equipment Wiring Instructions Use the NO contact on the 100S contactor as a permissive, for the drive to indicate that line power is present to the drive (Power Present Permissive). The contact will close when line power is present. A digital input on the PLC can be programed as the ready input. When the input is closed, the drive is ready to run. Use the NC contact on the 100S contactor as a reset for the 440R-D2252 safety relay. Use both NC contacts on the 100S in a relay string, wired in series. Wired in this string is a digital output on the PLC which will be programmed as a reset, when the 440R-D2252 needs to be reset. Wire the Y32 output on the 440R-D2252 relay, to a PLC digital input to indicate the Armor PowerFlex drive is not in an Emergency Stop condition (Estop OK). See Figure 9. Figure 9 - Standard Drive with E-Stop 3- Phase Source 9A 600V JTD 24V DC E-Stop K1 K1 Reset Relay Out From PLC K2 K2 Motor To PLC (E-stop OK)) K1 K2 24V Com To PLC Dig In (Power Present Permissive) 30 Rockwell Automation Publication 35-UM001G-EN-P - September 2024 Motor Motor Chapter 1 Armor PowerFlex Variable Frequency Drives Overview Safety Drives Configuration Armor PowerFlex safety drives (35S) are capable of Safe Torque Off (STO) via hardwired STO connections and integrated drive-based STO and SS1, and integrated controller-based safety functions like Safely Limited Speed (SLS). These examples illustrate some of the functional safety configuration options. Hardwired STO Armor PowerFlex safety drives use the STO connector for wiring external safety devices and cascading hardwired safety connections from one drive to another (see Figure 10). For details on hardwired STO, see Hardwired Safe Torque Off Function on page 100. IMPORTANT Safety inputs 0 and 1 support safety pulse test in hardwired safety operation. Safety inputs 2 and 3 do NOT support pulse test in hardwired mode. IMPORTANT In hardwired safety mode only, one of the two safety input connectors can be used (either safety input 0 and 1 or safety input 2 and 3). Connecting a cable and safety device to both safety inputs connectors, in hardwired safety mode, will cause a safety fault that cannot be reset. IMPORTANT In hardwired safety mode, the bi-polar safety output is not operational. It can only be used in integrated safety mode. Figure 10 - Hardwired Safe Torque Off EtherNet/IP (supports DLR) Programmable Controller Main Power Circuit Protection Ethernet cable Ethernet Managed Switch Ethernet cable User-supplied Safety Device Ethernet cable 120V AC 24V DC Power Supply Input - 0,1 Input - 2,3 Armor PowerFlex Drive with Integrated Safety (35S) Frame Size B Safety Device Feedback Armor PowerFlex Drive with Integrated Safety (35S) Frame Size A Input - 0,1 Input - 2,3 Safety Device Feedback Configurable I/O - 0,1 Configurable I/O - 0,1 24V DC Auxiliary/Control Power Ethernet cable Encoder 3-phase Power Rockwell Automation Publication 35-UM001G-EN-P - September 2024 31 Chapter 1 Armor PowerFlex Variable Frequency Drives Overview Integrated STO The GuardLogix or Compact GuardLogix safety controller issues the STO or SS1 command over the EtherNet/IP network and the Armor PowerFlex drive executes the command. In the example shown in Figure 11 on page 32, a drive without the safety configuration (35E) makes the standard I/O connection and a separate Armor PowerFlex safety drive (35S) makes the safety-only I/O connection. For details on integrated STO, see Integrated Safety Features on page 104. Figure 11 - Integrated Safe Torque Off (STO) or Timed Safe Stop (SS1) Safety Programmable Controller Ethernet cable Ethernet Managed Switch EtherNet/IP with CIP Safety (supports DLR) Ethernet cable Ethernet cable Main Power Circuit Protection EtherNet/IP DLR 120V AC 24V DC Power Supply Armor PowerFlex Drive with Integrated Safety (35S) Frame Size A Armor PowerFlex Drive (35E) Frame Size B Input - 0,1 Input - 2,3 Input - 0,1 Input - 2,3 Configurable I/O - 0,1 Configurable I/O - 0,1 24V DC Safety Inputs Safety Bipolar Output Auxiliary/Control Power Ethernet cable Encoder 3-phase Power 32 Rockwell Automation Publication 35-UM001G-EN-P - September 2024 Encoder Chapter 1 Armor PowerFlex Variable Frequency Drives Overview Integrated Safe Speed Monitoring Armor PowerFlex drives are capable of safe stop and safe speed monitor functions via drivebased and controller-based integrated safety over the EtherNet/IP network (see Figure 12). In this example, the SS1 stopping function is used in a standard and safety drive-based configuration with dual-feedback monitoring. For details on integrated STO, see Integrated Safety Features on page 104. For details on controller-based integrated safety, see Controller-based Safe Monitor Functions on page 124. Figure 12 - Integrated Safe Speed Monitored Safety Programmable Controller Ethernet cable Ethernet Managed Switch EtherNet/IP with CIP Safety (supports DLR) Ethernet cable Ethernet cable Main Power Circuit Protection Armor PowerFlex Drive with Integrated Safety (35S) Frame Size B 120V AC 24V DC Power Supply Input - 0,1 Input - 2,3 Configurable I/O - 0,1 24V DC Safety Inputs Safety Bipolar Output Armor PowerFlex Drive with Integrated Safety (35S) Frame Size A Input - 0,1 Input - 2,3 Configurable I/O - 0,1 Safety Inputs Safety Bipolar Output Auxiliary/Control Power Ethernet cable Encoder Safety encoder feedback is required for SS1, SLS, SDI, and SLP performance Encoder STO or timed SS1 performance 3-phase Power Rockwell Automation Publication 35-UM001G-EN-P - September 2024 33 Chapter 1 Armor PowerFlex Variable Frequency Drives Overview Notes: 34 Rockwell Automation Publication 35-UM001G-EN-P - September 2024 Chapter 2 Install the Armor PowerFlex Drive This chapter provides installation information. Unpack and Inspect The installer/customer is responsible for thoroughly inspecting the equipment before accepting the shipment from the freight company. Check the items that are received against the purchase order. If any items are damaged, it is your responsibility not to accept delivery until the freight agent has noted the damage on the freight bill. If any concealed damage is found during unpacking, it is again your responsibility to notify the freight agent. Leave the shipping container intact and request the freight agent to make a visual inspection of the equipment. Follow these steps to unpack and inspect the unit: • Remove all packing material, wedges, or braces from within and around the Armor PowerFlex controller. • Remove all packing material from the device or devices. • Check the items nameplate numbers against the purchase order. See Catalog Number Explanation on page 19 and for an explanation of the catalog number system that aids in nameplate interpretation. • Contact your local Allen-Bradley distributor if any items are missing. IMPORTANT Before the installation and startup of the drive, you must perform a general inspection of mechanical integrity (for example: loose parts, wires, connections, packing materials, and so on). IMPORTANT Locate and retain the red STO bypass plug that ships with the product. It can be used for product commissioning. See STO Bypass Operation on page 100. Storage The drive must remain in its shipping container before installation. If the equipment will not be used for some time, it must be stored according to the following instructions to maintain warranty coverage. • Store in a clean, dry location. • Store within an ambient temperature range of –25…+70 °C (–13…+158 °F). • Store within a relative humidity range of 5…95%, noncondensing. • Do not store equipment where it can be exposed to a corrosive atmosphere. • Do not store equipment in a construction area. • For storage duration that exceeds 2 years, also see Bus Capacitor Maintenance on page 242. Personal and Electrical Safety Precautions In addition to the precautions listed throughout this manual, the following statements, which are general to the system, must be read and understood. ATTENTION: Only trained and qualified personnel familiar with the controller and associated machinery can plan or implement the installation, startup, adjustment, and subsequent maintenance or repair of the system. You must have previous experience with and a basic understanding of electrical terminology, configuration procedures, required equipment, and safety precautions. Rockwell Automation Publication 35-UM001G-EN-P - September 2024 35 Chapter 2 Install the Armor PowerFlex Drive ATTENTION: An incorrectly applied or installed drive can damage components or reduce product life. Wiring or application errors, such as undersizing the motor, incorrect or inadequate AC supply, or excessive ambient temperatures, can result in malfunction of the system. ATTENTION: If this equipment is used in a manner not specified by the manufacturer, the protection that is provided by the equipment, could be impaired. ATTENTION: If a malfunction or damage occurs, make no attempt to repair. Return the module to the manufacturer for repair. Do not dismantle the module. ATTENTION: The National Electrical Code® (NEC®), NFPA®79, and any other governing regional or local code overrules the information in this manual. Rockwell Automation cannot assume responsibility for the compliance or proper installation of the Armor PowerFlex drive or associated equipment. A hazard of personal injury and/or equipment damage exists if codes are ignored during installation. ATTENTION: This unit has remote sources of power. Disconnect all power sources before the cover is removed. Failure to comply could result in death or serious injury. ATTENTION: Do not attempt to service internal components when the unit is energized. Complete lock out / tag out procedures for all input power sources. ATTENTION: The drive contains high-voltage capacitors. After removal of the main power supply, the capacitor discharge process can take 30 seconds to several minutes before a safe voltage is reached. Before working on the drive, or before servicing any device on the motor side, follow the procedure Test for Hazardous Voltage, starting on page 237, to verify that power is isolated and to verify that there are no hazardous voltages present. Use the test points under the power section door to confirm there are no hazardous AC line voltages (Test points: D1, D2, D3), and to confirm that the DC Bus capacitor bank voltage is at a safe level (Test points: DC+, DC-). After confirming no hazardous voltages are present at the test points under the power section door, open the power section cover to access the terminal block. Measure the input power on the L1, L2, and L3 of the exposed terminal block to verify that the power has been removed and that no hazardous voltage is present. Failure to verify that power is removed before working on the drive, or failure to verify that no hazardous voltages are present before working on the drive can result in personal injury or death. Darkened display light-emitting diode (LED) status indicators are not an indication that capacitors have discharged to safe voltage levels. SHOCK HAZARD: To avoid electrical shock, open the appropriate upstream protection (disconnect switch or branch circuit protection) before connecting and disconnecting cables. Risk of shock exists. Unused receptacles must be capped, the environmental rating might not be maintained with uncapped receptacles. Do not operate controls or open covers without appropriate personal protective equipment. Failure to comply can result in serious injury or death. 36 Rockwell Automation Publication 35-UM001G-EN-P - September 2024 Chapter 2 Install the Armor PowerFlex Drive WARNING: Circumstances that can cause an explosion could exist, which could lead to personal injury or death, property damage, or economic loss. Tripping of the instantaneous-trip circuit breaker is an indication that a fault current has been interrupted. Current-carrying components of a drive must be examined and replaced if they are damaged, to reduce the risk of fire or electrical shock. ATTENTION: Solid-state equipment has operational characteristics that differ from the characteristics of electromechanical equipment. Safety Guidelines for the Application, Installation, and Maintenance of Solid-state Controls, publication SGI-1.1, available from your local Rockwell Automation sales office or online at rok.auto/literature, describes some important differences between solid-state equipment and hard-wired electromechanical devices. Precautions for Cold Temperature Conditions ATTENTION: To make sure that the cables and the Armor PowerFlex connection points are at the same temperature within specifications at the time of installation, place the Armor PowerFlex and cables in an environment warmer than -25 °C (-13 °F) for a minimum of 1 hour, before connecting the cables to the Armor PowerFlex. ATTENTION: Before operating a motor with the Armor PowerFlex in a -25…-30 °C (-13…-22 °F) environment, power up the Armor PowerFlex for approximately 45 minutes, to allow the internal temperature to stabilize. Precautions for Motor Start/Stop ATTENTION: A contactor or other device that routinely disconnects and reapplies the AC line to the drive to start and stop the motor can cause drive hardware damage. The drive is designed to use start/stop command signals that start and stop the motor. When the start/stop command signal will also apply line side AC power concurrently, do not exceed one start/stop command signal per minute. Avoid Electrostatic Discharge ATTENTION: This Armor PowerFlex drive contains Electrostatic Discharge (ESD) sensitive parts and assemblies. Static control precautions are required when you install, test, service, or repair this assembly. Component damage can result if ESD control procedures are not followed. If you are not familiar with static control procedures, see an applicable ESD protection handbook. Environmental Considerations At the end of its life, this equipment must be collected separately from any unsorted municipal waste. Rockwell Automation Publication 35-UM001G-EN-P - September 2024 37 Chapter 2 Install the Armor PowerFlex Drive Lift Instructions If you have a Frame B drive, you must perform the following lift procedure. ATTENTION: All equipment and hardware that is used to lift the Armor PowerFlex drive must be properly sized and rated to lift and hold the weight of the drive safely. To guard against possible personal injury or equipment damage: • Inspect all hardware for proper attachment before the drive is lifted. • Do not allow any part of the drive or lift equipment to contact electrically charged conductors or components. • Do not subject the drive to high rates of acceleration or deceleration during a lift or transportation. • Do not allow personnel or their limbs directly beneath the drive during a lift. Lift and Mount the Drive Follow these steps to lift and mount the drive: 1. Remove the plug that covers the lifting hole, located on the top of the drive. 2. Tightly screw in the device-lifting metal eye bolt that is shipped with the drive. ATTENTION: The eye bolt must be fully screwed in place before proceeding. 3. Insert and secure the appropriately-rated lifting hardware to the eye bolt. Metal Eye Bolt Dimensions — mm (in) 26 .0 Device-lifting Eye Bolt ) .0 (1 14.0 (0.55) 16.0 3) (0.6 M6xP1.0 ATTENTION: To guard against equipment damage, verify that the hardware is securely connected to the correct lifting hole in the drive as shown. Do NOT use connectors or splash shield to lift the drive. 4. Slowly lift the drive to an upright position and carefully transport it to the installation location. 5. Install the drive using one of the specified orientations as described in Mounting Orientation. 6. After the drive is secured in place, remove the eye bolt and re-insert the plug. 38 Rockwell Automation Publication 35-UM001G-EN-P - September 2024 Chapter 2 Mounting Orientation Install the Armor PowerFlex Drive Standard orientation is with the X-axis horizontal (left-right), Y-axis vertically aligned with gravity, and the Z-axis out from a standard panel orientation; this results in the high-voltage connectors pointing toward the earth. Acceptable limits of deviation from the standard orientation are as follows: • Up to 60° tilt about the vertical axis (forward or back) • 90° rotation (with local disconnect pointing up) • 180° rotation (with high-voltage connectors pointing up) ATTENTION: For proper heat dissipation and product operation, mount in one of the orientations shown in Figure 13. These deviations from the standard orientation may result in thermal or power derating. For additional details, see Configure Motor Protection on page 172. Figure 13 - Mount Positions with Mounting Feet Shown (Frame Size A shown in examples) Standard Mount Front Front Front Front 90° Rotation Mount Standard Mount with adjusted feet positions Back Back 180° Rotation Mount Back Back Up to 60° Tilt Mount 60° Rockwell Automation Publication 35-UM001G-EN-P - September 2024 60° 39 Chapter 2 Install the Armor PowerFlex Drive Armor PowerFlex Drive Dimensions Dimensions are shown in millimeters (inches). Dimensions are not intended to be used for manufacturing purposes. All dimensions are subject to change. Figure 14 - Armor PowerFlex Frame Size A: Standard Mounting Position 406 (15.98) 143.8 (5.66) 365 (14.37) 248 227 (9.76) 203 (8.94) (7.99) 6.5 (0.26) 71 (2.80) 55 (2.17) 29.5 (1.16) 68.3 (2.69) 75.5 (2.97) 23.3 (0.92) 441 (17.36) 425 (14.37) 406 (15.98) 203 162 (7.99) (6.38) 6.5 (0.26) Alternate mounting bracket orientation 40 Rockwell Automation Publication 35-UM001G-EN-P - September 2024 Chapter 2 Install the Armor PowerFlex Drive Dimensions are shown in millimeters (inches). Dimensions are not intended to be used for manufacturing purposes. All dimensions are subject to change. Figure 15 - Armor PowerFlex Frame Size A: 180° Mount Position 406 (15.98) 365 (14.37) 203 227 248 (8.94)(7.99) (9.76) 6.5 (0.26) 143.8 (5.66) 71 (2.80) 55 (2.17) 29.5 (1.16) 75.5 (2.97) Rockwell Automation Publication 35-UM001G-EN-P - September 2024 68.3 (2.69) 23.3 (0.92) 41 Chapter 2 Install the Armor PowerFlex Drive Dimensions are shown in millimeters (inches). Dimensions are not intended to be used for manufacturing purposes. All dimensions are subject to change. Figure 16 - Armor PowerFlex Frame Size A: 90° Mount Position 143.8 (5.66) 203 (7.99) 162 (6.38) 71 (2.80) 58.3 (2.29) 103.3 (4.06) 451 (17.76) 430 (16.93) 406 (15.98) 105.5 (4.15) 59.5 (2.34) 6.5 (0.26) 42 55 (2.17) Rockwell Automation Publication 35-UM001G-EN-P - September 2024 Chapter 2 Install the Armor PowerFlex Drive Dimensions are shown in millimeters (inches). Dimensions are not intended to be used for manufacturing purposes. All dimensions are subject to change. Figure 17 - Armor PowerFlex Frame Size B: Standard Mounting Position 465.0 (18.31) 424.0 (16.69) 248.0 (9.76) 203.0 (7.99) 227.0 (8.94) 181.5 (7.15) 70.0 (2.76) 108.2 (4.26) 6.5 (0.26) 29.5 (1.16) 23.3 (0.92) 68.3 (2.69) 75.5 (2.97) Alternate mounting bracket orientation 203.0 (7.99) 162.0 (6.38) 500.0 (19.69) 484.0 (19.06) 465.0 (18.31) 6.5 (0.26) Rockwell Automation Publication 35-UM001G-EN-P - September 2024 43 Chapter 2 Install the Armor PowerFlex Drive Dimensions are shown in millimeters (inches). Dimensions are not intended to be used for manufacturing purposes. All dimensions are subject to change. Figure 18 - Armor PowerFlex Frame Size B: 180° Mount Position 68.3 (2.69) 29.5 (1.16) 70.0 (2.76) 75.5 (2.97) 108.2 (4.26) 23.3 (0.92) 465.0 (18.31) 181.5 (7.15) 6.5 (0.26) 44 Rockwell Automation Publication 35-UM001G-EN-P - September 2024 248.0 (9.76) 203.0 (7.99) 227.0 (8.94) 424.0 (16.69) Chapter 2 Install the Armor PowerFlex Drive Dimensions are shown in millimeters (inches). Dimensions are not intended to be used for manufacturing purposes. All dimensions are subject to change. 181.5 (7.15) Figure 19 - Armor PowerFlex Frame Size B: 90° Mount Position 6.5 (0.26) Rockwell Automation Publication 35-UM001G-EN-P - September 2024 105.5 (4.15) 59.5 (2.34) 510.0 (20.08) 489.0 (19.25) 465.0 (18.31) 103.3 (4.06) 108.2 (4.26) 58.3 (2.29) 203.0 (7.99) 162.0 (6.38) 70.0 (2.76) 45 Chapter 2 Install the Armor PowerFlex Drive Wiring and Workmanship Guidelines In addition to conduit and seal-tite raceway, it is acceptable to use cable that is rated Tray Cable Exposed Runs (TC-ER), for power and control wiring on Armor PowerFlex installations. The National Electrical Code (NEC) and NFPA 79 outline the following guidance for installations in the USA and Canada. In industrial establishments where the conditions of maintenance and supervision verify that only qualified persons service the installation, and where the exposed cable is continuously supported and protected against physical damage, by using mechanical protection, such as struts, angles, or channels, Type TC tray cable that complies with the crush and impact requirements of Type MC (Metal Clad) cable and is identified for such use with the marking Type TC-ER (Exposed Run) shall be permitted between a cable tray and the utilization equipment or device as open wiring. The cable shall be secured at intervals not exceeding 1.8 m (6 ft) and installed in a good workmanlike manner. Equipment grounding for the utilization equipment shall be provided by an equipment grounding conductor within the cable. While the Armor PowerFlex drive is intended for installation in factory floor environments of industrial establishments, the following must be considered when locating the Armor PowerFlex drive in the application: • Cables that include control voltage cables, for example, 24V DC and communications, are not to be exposed to operator or building traffic on a continuous basis. • Location of the Armor PowerFlex drive to minimize exposure to continual traffic is recommended. If location to minimize traffic flow is unavoidable, other barriers to minimize inadvertent exposure to the cabling must be considered. • Cables must be routed to minimize inadvertent exposure and/or damage. • If conduit or other raceways are not used, we recommend that strain relief fittings be used when installing the cables for the control and power wiring through the conduit openings. • Power cabling, such as three-phase, source brake, and dynamic brake, must be kept at least 150 mm (6 in.) away from the EtherNet/IP network and I/O cables to avoid noise issues. See Wiring on page 47 for additional cable location requirements. Electromagnetic Compatibility The following guidelines are provided for Electromagnetic Compatibility (EMC) installation compliance. Cabling and Grounding IMPORTANT For EMC conformity, the motor cable connector that is selected must provide good 360° contact and low transfer impedance from the shield or armor of the cable to the conduit entry plate at both the motor and the Armor PowerFlex drive, for electrical bonding. The motor cable must be kept as short as possible to avoid electromagnetic emissions and capacitive currents. CE conformity of Armor PowerFlex drive with EMC Directive does not confirm that the entire machine installation complies with CE EMC requirements. IMPORTANT For EMC conformity, the maximum length of the safety I/O cable is limited to 98.4 ft (30 m). The Electromagnetic Interference (EMI) filter can achieve relatively high ground leakage currents. Therefore, the filter must only be used in installations that are solidly grounded (bonded) to the building power distribution ground. Grounding must not rely on flexible cables and must exclude any form of plug or socket that would permit inadvertent disconnection. Some local codes can require redundant ground connections. The integrity of all connections must be periodically checked. 46 Rockwell Automation Publication 35-UM001G-EN-P - September 2024 Chapter 2 Install the Armor PowerFlex Drive Wiring Wire in an industrial control application can be divided into three groups: power, control, and signal. The following recommendations for physical separation between these groups, are provided to reduce the coupling effect: • Minimum spacing between different wire groups in the same tray must be 16 cm (6 in.). • Wire runs outside an enclosure must be run in conduit or have shielding/armor with equivalent attenuation. • Different wire groups must be run in separate conduits. • Minimum spacing between conduits that contain different wire groups must be 8 cm (3 in.). Ethernet Cable Ferrite Cores If you are installing a series A device, you must install the two provided ferrite cores on each Ethernet cable to comply with CE. For details, see the Armor PowerFlex Drives Specifications Technical Data, publication 35-TD001. Configuration Constraints ATTENTION: PWM carrier frequency parameters must remain at default to comply with CE. Product Grounding Grounding is done for two basic reasons: safety, and noise containment or reduction. While the safety ground scheme and the noise current return circuit can sometimes share the same path and components, they must be considered different circuits with different requirements. The objective of grounding is to verify that all metal work is at the same ground (or Earth) potential at power frequencies. Impedance between the drive and the building scheme ground, must conform to the requirements of national and local industrial safety regulations or electrical codes. These requirements vary based on country, type of distribution system, and other factors. Periodically check the integrity of all ground connections. General safety dictates that all metal parts are connected to earth with separate copper wire or wires of the appropriate gauge. To determine the proper conductor size, see the NEC table 250.122 or your local electrical code. Most equipment has specific provisions to connect a ground and PE (protective earth) directly to it. The following considerations apply to ungrounded and high resistive distribution systems: ATTENTION: The Armor PowerFlex drive contains protective Metal Oxide Varistors (MOVs) that are referenced to a ground. These devices must not be disconnected or installed on an ungrounded and high resistive distribution system. ATTENTION: Do not apply the EMI filter to grounded or ungrounded delta power source. The EMI requires a solidly grounded wye (Y) power source (for example, 480/277 or 400/230V AC, 3-phase power source). If applied to a grounded or ungrounded 480V AC delta power source, the EMI filter maybe damaged. The installer can connect the product ground in two different ways. • The first method is to use the conduit/cord gland plate or the factory installed quick connect power connectors. • The second method is to connect the device’s external ground to a solid earth ground connection. Rockwell Automation Publication 35-UM001G-EN-P - September 2024 47 Chapter 2 Install the Armor PowerFlex Drive ATTENTION: The Armor PowerFlex drive must be installed in a solidlygrounded (Delta/Wye with Grounded Wye Neutral) system. The Armor PowerFlex requires a solidly-grounded system because it provides added protection and safety to the system. A solidly grounded system provides the following protection and safety features: • Controlled path for common mode noise current produced by VFD • Consistent line-to-ground voltage reference that minimizes insulation stress • Accommodation for system surge protection schemes For additional information, see Wiring and Grounding Guidelines for Pulse-width Modulated (PWM) AC Drives, publication DRIVES-IN001. Armor PowerFlex External Ground If the product is mounted to a non-grounded surface, the installer must use a second ground that uses the external ground point. The ground wire is sized according to the application needs and your local electrical code. See the National Electrical Code (NEC) NFPA 70 and/or the Electrical Standard for Industrial Machinery, NFPA 79 for proper installation details. 48 Rockwell Automation Publication 35-UM001G-EN-P - September 2024 Chapter 2 Install the Armor PowerFlex Drive The ground must be connected to earth ground. This ground point must be connected to adjacent building ground (girder, joist), a floor ground rod, busbar, or building ground grid. Grounding points must comply with national and local industrial safety regulations or electrical codes. Some codes can require redundant ground paths and periodic examination of connection integrity. ATTENTION: To avoid electrolytic corrosion on the external earth terminal, avoid the spraying of moisture directly on the terminal. When used in washdown environments apply a sealant or other corrosion inhibitor on the external ground terminal to minimize any negative effects of galvanic or electro-chemical corrosion. Ground connections must be inspected regularly. Shielding and Grounding of Motors and Motor Cables The motor frame or stator core must be connected directly to the protective earth (PE) connection with a separate ground conductor. We recommend that each motor frame is grounded to building ground at the motor. Motor Cable Considerations Most recommendations about motor cable address issues come from the nature of the drive output. A pulse width modulation (PWM) drive creates AC motor current by sending DC voltage pulses to the motor in a specific pattern. These pulses affect the wire insulation and can be a source of electrical noise. The rise time, amplitude, and frequency of these pulses must be considered when choosing a wire/cable type. The choice of cable must consider: 1. The effects of the drive output after the cable is installed 2. The need for the cable to contain drive output noise 3. The amount of cable-charging current available from the drive 4. Possible voltage drop (and subsequent loss of torque) for long wire runs Keep the motor cable lengths less than 14 m (45.9 ft) unless otherwise noted in the device specifications. Unshielded Motor Cable An unshielded motor cable is allowed for installations that do not require EMC compliance. The use of cables without shielding is generally acceptable for installations where drive electrical noise does not interfere with the operation of other devices such as: communication cards, photoelectric switches, weigh scales, and others. Be certain the installation does not require shielded cable to meet specific EMC standards for CE, RCM, FCC and any other applicable standards. The type of installation determines the cable specifications. ATTENTION: Shielded motor cable is mandatory for EMC emission compliant installations. Power Considerations The following items should be considered for the power circuit design. ATTENTION: As a standalone unit, this product does not comply with the harmonic emission and harmonic immunity requirements per EN 61000-3-2 and EN 61000-4-13, as referenced in EN 61800-3. It is thus only intended for use within a system which has been verified by the end user to meet these requirements. The system may use a 5%- line reactor for achieving compliance to these limits. Cat. No. 1321-3R18-C line reactor is an available option. Rockwell Automation Publication 35-UM001G-EN-P - September 2024 49 Chapter 2 Install the Armor PowerFlex Drive Add Line Reactor To minimize harmonics, we recommend adding a line reactor to the Armor PowerFlex input power using these guidelines. • Rated voltage: 480V AC, minimum • Rated current: The line reactor rated current should be based on the real current, not on the output rating of the Armor PowerFlex drive. For example, you could have an Armor PowerFlex Frame B drive rated at 17 A, but your application has a motor that draws only 10 A, then 10 A should be used as the criteria to select the line reactor rated current. • Impedance: 5% For additional information on selecting line reactors, see Line Reactors and AC Drives White Paper, publication DRIVES-WP016. Branch Circuit Protection Requirements When using ArmorConnect three-phase power media or fixed wire (such as cord or conduit), with the Armor PowerFlex drive, protective devices that meet local applicable electrical codes can be used for the feeder branch circuit protection. The feeder protective device is intended to protect the line-side power conductors. ATTENTION: Select the branch circuit protection that complies with NFPA 79 or NFPA 70 (NEC) and any other governing regional or local codes. WARNING: If the branch circuit protective device trips, you must verify that the Source Brake function is still operational before putting the equipment back in service. If the source brake function is not working properly, loss of brake function or motor damage can occur. WARNING: Do not install the Armor PowerFlex drive where the maximum available fault current exceeds the product rating. Group Motor Installations for USA and Canada Markets The Armor PowerFlex drive integrates the motor branch short circuit and ground fault protection devices and it is considered self-protected. Therefore, no additional motor control branch circuit protection is required. Multiple Armor PowerFlex drives can be applied in a group application; as each Armor PowerFlex is self-protected. The installer must follow the local electrical codes for the protection of the feeder conductors using recommended branch circuit protection devices. Motor cable assemblies are not supplied and have to be ordered separately. To comply with the UL Listing of the drive, use the Rockwell Automation® motor cable assembly that is specified by the instructions for the drive. See the On-Machine Media for Armor PowerFlex, ArmorStart, and ArmorConnect Products Selection Guide, publication, 280PWR-SG001. Figure 20 on page 51 shows an example that illustrates installations involving multiple motors with a single Branch Circuit Protection Device (BCPD) protecting the entire “Group”. 50 Rockwell Automation Publication 35-UM001G-EN-P - September 2024 Chapter 2 Install the Armor PowerFlex Drive Figure 20 - Group Motor Installation Three-phase Power Armor PowerFlex Drive Size per your local code, such as NFPA 70 (NEC) or NFPA 79 Branch Circuit Protection and Ground Fault Device (up to 100 kA SCCR) Armor PowerFlex Drive Armor PowerFlex Drive Motor Motor Motor Three-phase Power Armor PowerFlex Drive Armor PowerFlex Drive Motor Motor Rockwell Automation offers a wide range of branch circuit protection that will protect your branch circuit conductors that feed power to your Armor PowerFlex drive group. Our molded case circuit breakers have multiple frame sizes to accommodate your required current ratings and breaking capabilities. These breakers provide protection of circuits against overload, short circuit, and ground fault. For more information, see Molded Case Circuit Breakers. Our disconnect switches are available in both fixed- and variable-depth styles with flange- or door-mounting styles. Our switches are NEMA, IEC, and UL rated. We offer a variety of fused and non-fused versions from 20…1250 A, in both open and enclosed configurations. For more information, see Fusible Disconnect Switches. Auxiliary Power Connections The 24V DC auxiliary power is supplied by one or two external power supplies or by the optional internal power supply (IPS). If you choose an external power supply configuration, our current offering of auxiliary power cables and receptacles have an IP66, UL Type 1/12 rating. You must confirm that this rating is acceptable for the intended application. Auxiliary power provides: • Input/sensor power — sourced from unswitched 24V DC • Output power — sourced from switched 24V DC • Communications power — sourced from unswitched 24V DC The maximum Auxiliary Power IN cable length is 20 m (65.6 ft). A maximum of two cables can be connected in series to achieve the desired overall length — not to exceed 20 m (65.6 ft). Power Supply Requirements You can apply the Armor PowerFlex drive with an external 24V DC auxiliary power supply. The external auxiliary power supply will power up communication, inputs, and outputs. The external power supply provides unswitched and switched 24V DC to the Armor PowerFlex drive. You can install, configure, and operate the I/O without three-phase power connected, if you order an Armor PowerFlex drive with the external power supply configuration and if you provide external unswitched 24V DC to the product. To use Armor PowerFlex, you must choose a power supply that is suitable for your application and field I/O requirements. The Armor PowerFlex drive can source a class 2 circuit according to the NEC 725.60 standard, which covers unswitched power (for sensors) and/or switched power (for actuators). These are the requirements for an external auxiliary power supply: • Rated for 24V DC nominal (tolerance 24V DC ±15%) • The supply should be PELV or SELV type • The supply must be capable of 150% current boost power for at least one second Rockwell Automation Publication 35-UM001G-EN-P - September 2024 51 Chapter 2 Install the Armor PowerFlex Drive If you choose an external power supply, you must set the external power supply jumper to the type of your power supply (either PELV or SELV). The external power supply jumper is on the I/O board, below the encoder power supply switch (see Figure 21). See Remove Front Logic Cover on page 70 for information on how to gain access to the I/O board. Figure 21 - External Power Supply Jumper External Power Supply Jumper shown in the default SELV position FE BYPASS As an option, you can select an internal power supply (IPS). With this option selected, you do not require an external power supply. The Armor PowerFlex drive will internally source the 24V DC power for communications, inputs, and outputs. The 24V DC IPS is sourced from the three-phase power coming into the Armor PowerFlex drive. The IPS circuitry connects to the line side of the local disconnect, which means that when the local disconnect on the Armor PowerFlex drive is in the Off position, the IPS will continue to provide 24V DC power. To shutdown the IPS output power, the main disconnect must be set to the Off position, to remove all three-phase power coming into the Armor PowerFlex drive. When selecting the internal power supply option for the Armor PowerFlex (see Internal Power Supply Wiring and Local Disconnect Behavior on page 54), it can be considered a class 2 circuit as per the NEC 725.60 standard. This class covers unswitched power (for sensors) and/ or switched power (for actuators). For more details, see the Armor PowerFlex AC Drives Specifications, publication 35-TD001. 52 IMPORTANT There is an instantaneous inrush of 6.5 A for 15 milliseconds. The external 24V DC power supply must be able to support this demand when multiple Armor PowerFlex drives are turned ON simultaneously. For supplies without this capacity, we recommend applying unswitched power first and after a 2…4 second delay, apply switched power. If auxiliary power falls below 20.4V DC, there is a higher risk of communications issues or device faults. IMPORTANT Both a switched and unswitched 24V supply from this source are provided to the safety subsystem. The installer is responsible for providing safety power that is PELV or SELV rated. Rockwell Automation Publication 35-UM001G-EN-P - September 2024 Chapter 2 Install the Armor PowerFlex Drive IMPORTANT To comply with the CE Low Voltage Directive (LVD), all connections to this equipment must be powered from a source compliant with the following: • Safety extra low voltage (SELV) Supply • Protected extra low voltage (PELV) Supply • To comply with UL/cUL requirements, this equipment must be powered from a source compliant with the following: IEC 60950-1 Ed. 2.1, Clause 2.2 - SELV Circuits IMPORTANT The switched and unswitched circuits are Limited Voltage/Limited Current (LV/LC) according to UL 61800-5-1, which is equivalent to Limited-power circuits per 725.60 (A) (4) - Power Sources for Class 2 and Class 3 Circuits. Field Earth Jumper There is a “Field Earth” (FE) jumper that is located on the I/O board. The purpose of the FE jumper is to filter the noise on the auxiliary (AUX) power rail. • Connect the FE jumper to pin 1 and pin 2 of the B17 connector to configure the drive into the Field Earth Not Connected (FENC) mode. • Connect the FE jumper to pin 2 and pin 3 of the B17 connector to configure the drive into the Field Earth (bypass) mode. Figure 22 - FE Jumper FE BYPASS FE Jumper - shown in default FENC mode The default position of the FE jumper is in the FENC mode. Do not change this position if there are other Armor PowerFlex drives that are not daisy-chained with AUX 24V power, because the Field Earth pin on the AUX POWER IN connector is connected to field earth irrespective of FE jumper position. Change the jumper position to the Field Earth mode when there are other Armor PowerFlex drives that are daisy chained with AUX 24V power. This helps to filter the noise on the AUX 24V power cable in this daisy-chained drive configuration. See Table 5. Table 5 - Field Earth Jumper Configuration Field Earth Jumper Position Pin 1 to Pin 2 (default) Pin 2 to Pin 3 Description Field Earth Not Connected (FENC) mode: For multiple drives that are not daisy chained with 24V auxiliary power. Field Earth mode: For multiple drives that are daisy chained with 24V auxiliary power. Rockwell Automation Publication 35-UM001G-EN-P - September 2024 53 Chapter 2 Install the Armor PowerFlex Drive Internal Power Supply Wiring and Local Disconnect Behavior IMPORTANT Config. I/O is based on switched power reference however, if Config. I/O is provided with its ground reference (SW_COM), the input will be read regardless of the EMD disconnect state. Figure 23 - Internal Power Supply (optional) Three-phase Power Line Input Power Off On Disconnect (EMD) Manual Switch 24V DC Internal Power Supply EMD - Aux. Switched Power Unswitched Power Invertor Convertor Comm. Output Power to Motor Input Config. I/O Encoder Safety Input Safety Safety Bipolar Output Output Motor En. Motor Single External Power Supply Wiring and Local Disconnect Behavior Figure 24 - Single External Power Supply Three-phase Power User Supplied External Power Supply Line Input Power Off On 24V DC EMD - Aux. Switched Power Unswitched Power Disconnect (EMD) Manual Switch Invertor Convertor Output Power to Motor Comm. Input Config. I/O Encoder Safety Input Safety Output Safety Bipolar Output Motor En. Motor Multiple External Power Supply Wiring and Local Disconnect Behavior Figure 25 - Multiple External Power Supplies Three-phase Power User Supplied External Power Supply 1 Line Input Power Off On 24V DC EMD - Aux. Switched Power Disconnect (EMD) Manual Switch Invertor 24V DC Convertor Unswitched Power External Power Supply 2 User Supplied Output Power to Motor Comm. Input Config. I/O Motor 54 Rockwell Automation Publication 35-UM001G-EN-P - September 2024 Encoder Safety Input Safety Safety Bipolar Output Output Motor En. Chapter 2 Install the Armor PowerFlex Drive Terminal Block Power In Ground terminal R S T Power Out R S T Ground Terminal Signal Terminal Size Ground Line 1 (input) Line 2 (input) Line 3 (input) 8…18 AWG Power Terminal Location and Internal Wiring Figure 26 - Armor PowerFlex Safety Drive Terminals Three-phase Power Output Input Wire Strip Length 0.42 ± 0.03 in. (10.7 ± 0.8 mm) Line 1 (output) Line 2 (output) 8…18 AWG Line 3 (output) Ground Figure 27 - Bulletin 35S — Integrated Safety Version Armor PowerFlex Drive Internal Wiring Dynamic Brake Armor PowerFlex Safety Drive Internal to the Armor PowerFlex Drive Dynamic Brake Resistor Module Socket View Plug View Thermal Switch +DC Bus (P) Thermal Switch Input Voltage (>50V) -BR -DC Bus Voltage (<50V) Chopper IGBT Chassis 5 1 5 1 4 2 4 2 3 3 Chassis Dynamic Brake Resistor —Voltage Test Points R_Line_In Relay R Filter in R S_Line_In Relay S Filter in S T_Line_In EMI Filter Board EMD Disconnect PGND S_Line_In Customer replaceable fuses INT_24V SW_24V SW_24V UNSW_24V UNSW_24V IMPORTANT EM_FUSE_S SW_24V Control Section UNSW_24V UNSW_24V Ethernet EM_BRAKE_R EM_FUSE_R EM Brake Circuit EM Brake Fuse Detection SW_24V 24V Power Supply Standard Inputs Motor Power Section EM_BRAKE_S EM Brake Fuses Safety Output EM Brake Voltage Feedback Conťgurable I/O Encoder PS Selector UNSW_24V UNSW_24V External Auxiliary 24V Supply PELV/SELV rated (Optional) FL2 S U V W PE Inverter Section EM Brake Current Feedback FL2 R DC Bus Feedback GF P2 Detection BUS CAP N D3 3-phase Voltage Feedback Internal 24V Supply (Optional) Pre-charge Converter Section (Diode Front End) Disconnect Switch R_Line_In P1 P D2 Filter in T Relay T Line Fuses 3-phase Input D1 Safety Inputs LEDs Push Buttons IP Switches The Electronic Motor Disconnect (EMD) board monitors when the Armor PowerFlex gets a fault. The CPU (Armor PowerFlex firmware) provides a signal to the EMD indicating if a fault is present. When a fault is present, the EMD disconnect opens. When a Dynamic Brake is used, this functionality will serve as an isolating contactor. For additional information about the EMD, see the Local Disconnect Behavior on page 66. For details about not using an isolating contactor, see Configure Dynamic Brake on page 185. Rockwell Automation Publication 35-UM001G-EN-P - September 2024 55 Chapter 2 Install the Armor PowerFlex Drive Figure 28 - Bulletin 35E — Armor PowerFlex Standard Drive Terminals Terminal Block Power In Ground terminal R S T Power Out R S T Ground Terminal Three-phase Power Output Input Wire Strip Length 0.42 ± 0.03 in. (10.7 ± 0.8 mm) Signal Terminal Size Ground Line 1 (input) Line 2 (input) Line 3 (input) 8…18 AWG Line 1 (output) Line 2 (output) 8…18 AWG Line 3 (output) Ground Figure 29 - Bulletin 35E — Standard Version Armor PowerFlex VFD Internal Wiring Dynamic Brake Armor PowerFlex Drive Internal to the Armor PowerFlex Drive Dynamic Brake Resistor Module Socket View Plug View Thermal Switch +DC Bus (P) Thermal Switch Input Voltage (>50V) -BR -DC Bus Voltage (<50V) Chopper IGBT Chassis 5 4 3 1 5 1 2 4 2 3 Chassis Dynamic Brake Resistor —Voltage Test Points R_Line_In Relay R Filter in R S_Line_In Relay S Filter in S T_Line_In Line Fuses EMI Filter Board EMD Disconnect PGND S_Line_In SW_24V Internal 24V Supply (Optional) FL2 S SW_24V IMPORTANT 56 Control Section UNSW_24V EM Brake Circuit EM_BRAKE_S UNSW_24V Standard Inputs EM Brake Voltage Feedback Conťgurable I/O Encoder PS Selector UNSW_24V UNSW_24V Ethernet EM_FUSE_S SW_24V UNSW_24V UNSW_24V EM_BRAKE_R EM_FUSE_R EM Brake Fuse Detection SW_24V 24V Power Supply Motor Power Section EM Brake Fuses Customer replaceable fuses INT_24V U V W PE Inverter Section EM Brake Current Feedback FL2 R DC Bus Feedback GF P2 Detection BUS CAP N Disconnect Switch R_Line_In P1 Pre-charge Converter Section (Diode Front End) D3 3-phase Voltage Feedback External Auxiliary 24V Supply PELV/SELV rated (Optional) P D2 Filter in T Relay T 3-phase Input D1 LEDs Push Buttons IP Switches The Electronic Motor Disconnect (EMD) board monitors when the Armor PowerFlex gets a fault. The CPU (Armor PowerFlex firmware) provides a signal to the EMD indicating if a fault is present. When a fault is present, the EMD disconnect opens. When a Dynamic Brake is used, this functionality will serve as an isolating contactor. For additional information about the EMD, see the Local Disconnect Behavior on page 66. For details about not using an isolating contactor, see Configure Dynamic Brake on page 185. Rockwell Automation Publication 35-UM001G-EN-P - September 2024 Chapter 2 Install the Armor PowerFlex Drive Connector Pinouts and Cable Torques IMPORTANT You must connect cables properly and use sealing caps or dust covers as needed, to achieve specified enclosure ratings. Power and Motor Connector Pinouts and Cable Torques IMPORTANT The Armor PowerFlex drive includes a rubber sealing boot which is required to be installed when the drive’s 3-phase power out circuit is not in use. This condition can apply when Armor PowerFlex drives are not daisy chained together or when the drive is the last unit in a daisy chain configuration. Auxiliary Power IN (M12, plug) FE 1 4 2 3 Pin 1: +24V unswitched power (sensor power) (brown) Pin 2: Switched power ground (white) Cable Connector Torque Pin 3: Unswitched power ground (blue) 0.6…0.65 N•m (5.3…5.8 lb•in) Pin 4: +24V switched power (black) FE: FE pass-through jumper (gray) Auxiliary Power OUT (M12, socket) Pin 1: +24V unswitched power (sensor power) (brown) Pin 2: Switched power ground (white) Cable Connector Torque Pin 3: Unswitched power ground (blue) 0.6…0.65 N•m (5.3…5.8 lb•in) Pin 4: +24V switched power (black) FE: FE pass-through jumper (gray) FE 1 4 2 3 Dynamic Brake Connection (M22, socket) 5 4 3 Pin 1: DB temp SWPin 2: DB resistor T1 Pin 3: Chassis (PE) Pin 4: DB resistor T2 Pin 5: DB temp SW+ 1 2 Cable Connector Torque 1.69 N•m (15 lb•in) Motor without EM brake (M29, socket) 4 1 3 2 Pin 1: Motor T1 (black) Pin 2: Motor T2 (white) Pin 3: Motor T3 (red) Pin 4: Ground (green/yellow) Cable Connector Torque 2.26 N•m (20 lb•in) Motor with EM brake (M29, socket) 3 4 2 1 7 5 6 Pin 1: Motor T1 (black) Pin 2: Motor T2 (white) Pin 3: Motor T3 (red) Pin 4: Ground (green/yellow) Pin 5: EM brake T1 Pin 6: EM brake T2 Pin 7: Drain wire Cable Connector Torque 2.26 N•m (20 lb•in) Three-Phase Power IN with Round Connector (M35, plug) 4 1 3 2 Pin 1: L1 (black) Pin 2: Ground (green/yellow) Pin 3: L3 (red) Pin 4: L2 (white) Use when application requires UL or CE compliance as standard Cable Connector Torque 4.52 N•m (40 lb•in) Rockwell Automation Publication 35-UM001G-EN-P - September 2024 57 Chapter 2 Install the Armor PowerFlex Drive Three-Phase Power OUT with Round Connector (M35, socket) 1 4 2 3 Pin 1: L1 (black) Pin 2: Ground (green/yellow) Pin 3: L3 (red) Pin 4: L2 (white) Use when application requires UL or CE compliance as standard Cable Connector Torque 4.52 N•m (40 lb•in) Three-Phase Power IN with Square Connector — plug 4 3 PE 12 2 11 1 Use when application requires CE compliance as standard Pin 1: Line input 1 Pin 2: Line input 2 Pin 3: Line input 3 Pin 4: not used Pin 11: not used Pin 12: not used Center Pin: Chassis (PE) Cable Connector Torque Snap in place (no torque) Three-Phase Power OUT with Square Connector — socket 4 3 11 PE 1 12 2 Pin 1: Line input 1 Pin 2: Line input 2 Pin 3: Line input 3 Pin 4: not used Pin 11: not used Pin 12: not used Center Pin: Chassis (PE) Use when application requires CE compliance as standard Cable Connector Torque Snap in place (no torque) Standard I/O Connector Pinouts and Cable Torques ATTENTION: No power should be applied to the input connectors. The 24V and Chassis (PE) terminals are only meant to supply power from the Armor PowerFlex drive to external sensor devices (power output). If the drive is powered via the input connectors, there is no fuse protection on the 24V supply and an input power overcurrent fault will occur, that cannot be cleared. The following characteristics are common to the I/O connections for Armor PowerFlex standard versions: • 5-pin female connectors (M12) • Four fixed inputs (two per connector) • Two configurable points on one connector I/O Standard Input (M12, socket) 1 4 5 2 3 Input Pin 1:+24V unswitched (sensor) power Pin 2: Input n+1 Pin 3: Input Common Pin 4: Input n Pin 5: Chassis (PE) Cable Connector Torque 0.5…0.6 N•m (4.4…5.3 lb•in) (hand tight) I/O Configurable Input or Output (M12, socket) 1 4 58 5 2 3 Input Pin 1: +24V switched power Pin 2: Input 1 Pin 3: I/O Common Pin 4: Input 0 Pin 5: Chassis (PE) Output Pin 1: Not used (+24V) Pin 2: Output 1 Pin 3: I/O Common Pin 4: Output 0 Pin 5: Chassis (PE) Rockwell Automation Publication 35-UM001G-EN-P - September 2024 Cable Connector Torque 0.5…0.6 N•m (4.4…5.3 lb•in) (hand tight) Chapter 2 Install the Armor PowerFlex Drive Safety I/O Connector Pinouts and Cable Torques The following input and output characteristics are common to the I/O connections for Armor PowerFlex safety versions: • Four single-channel or two dual-channel 24V DC safety input • Two single-channel 24V DC test output • One bipolar 24V DC safety output For specific user safety I/O wiring examples, see Safety Drives Configuration on page 31. I/O Safety: Configurable 2-channel safety input with test outputs (M12, socket) 1 5 4 Pin 1: Test Output 1 Pin 2: Safety Input n+1 Pin 3: Common Pin 4: Safety Input n Pin 5: Test Output 0 2 3 IMPORTANT Cable Connector Torque 0.5…0.6 N•m (4.4…5.3 lb•in) (hand tight) When applied as a CIP Safety device, there are only two test outputs that can be assigned to the two pairs of safety inputs. When applied in hardwired STO (See Safe Torque Off and Safe Monitor Functions on page 23), the test outputs are fixed to one pair of safety inputs. I/O Safety: Configurable bipolar output (M12, socket) 1 5 4 Pin 1: NC (no connection) Pin 2: Output n (N) sinking Pin 3: Output Power Common Pin 4: Output n (P) sourcing Pin 5: Output Power Common 2 3 Cable Connector Torque 0.5…0.6 N•m (4.4…5.3 lb•in) (hand tight) I/O Safety: Jumper Bypass Plug Used when no cables are connected to the safety inputs. Only one jumper is required and can be attached to Safety In 0/1 or Safety In 2/3 (but not both), to enable torque in hardwired mode. 2 3 5 Pin 1: connect to Pin 2 Pin 2: connect to Pin 1 Pin 3: NC (no connection) Pin 4: connect to Pin 5 Pin 5: connect to Pin 4 1 4 Cable Connector Torque 0.5…0.6 N•m (4.4…5.3 lb•in) (hand tight) Ethernet Connector Pinouts and Cable Torque The Armor PowerFlex drive uses a sealed X-coded M12 (micro) style Ethernet connector. EtherNet 1 GB (M12, socket) 1 8 2 3 7 6 4 5 Pin 1: D1+ (white/orange) Pin 2: D1- (orange) Pin 3: D2+ (white/green) Pin 4: D2- (green) Pin 5: D4+ (white/brown) Pin 6: D4- (brown) Pin 7: D3- (white/blue) Pin 8: D3+ (blue) Cable Connector Torque 0.5…0.6 N•m (4.4…5.3 lb•in) (hand tight) Rockwell Automation Publication 35-UM001G-EN-P - September 2024 59 Chapter 2 Install the Armor PowerFlex Drive Encoder Connector Pinouts and Cable Torque Encoder systems are sensors that are mounted on the rotor shaft that can record information about the instantaneous rotor position and speed. Encoder (M12, socket)(a) 1 7 6 Encoder Wiring Examples 2 3 8 5 4 Pin 1: Output A, SIN- (white) Pin 2: Output A, SIN+ (brown) Pin 3: Output B, COS- (green) Pin 4: Output B, COS+ (yellow) Pin 5: not used (grey) Pin 6: not used (pink) Pin 7: Encoder supply ground (blue) Pin 8: Encoder supply power (5V or 12V) (red) Cable Connector Torque 0.5…0.6 N•m (4.4…5.3 lb•in) (hand tight) Sin-Cosin Encoder Wiring Example Sin-Cosin Encoder Drive Side Motor Side ENCODER CONNECTOR 1. A_SIN2. A_SIN+ 3. B_COS4. B_COS+ BN WH BK PK 0. SHIELD SinSin+ CosCos+ Outer Shield 5. NC 6. NC BU 7. COM 8. POWER RD DGND +UB M12 / 8PIN / A-code / Male When using a safety sine/cosine encoder, the cable shield must be connected to ground on both sides to ensure fault-free operation. (On the Armor PowerFlex side it is done by M12 connector, on the encoder side it can be typically done by connecting the shield of the cable with the connector housing.) If you use an encoder without cable shield connection capability, it is acceptable to leave the shielding grounded only on the Armor PowerFlex side. (a) The maximum Encoder cable length is 20 m (65.6 ft). A maximum of two cables can be connected in series to achieve the desired overall length — not to exceed 20 m (65.6 ft). 60 Rockwell Automation Publication 35-UM001G-EN-P - September 2024 Chapter 2 Install the Armor PowerFlex Drive Single-ended, Single-channel Encoder Wiring Example Single Ended Single channel Encoder Drive Side Motor Side ENCODER CONNECTOR 1. A_SIN2. A_SIN+ /Enc A BN 3. B_COS- Enc A /Enc B 4. B_COS+ Enc B 0. SHIELD SHIELD 5. NC 6. NC BU 7. COM RD 8. POWER DC Return DC +Input M12 / 8PIN / A-code / Male Single-ended, Dual-channel Encoder Wiring Example Single Ended Dual channel Encoder Drive Side Motor Side ENCODER CONNECTOR 1. A_SIN2. A_SIN+ /Enc A BN /Enc B 3. B_COS4. B_COS+ Enc A BK 0. SHIELD Enc B SHIELD 5. NC 6. NC 7. COM 8. POWER BU RD DC Return DC +Input M12 / 8PIN / A-code / Male Rockwell Automation Publication 35-UM001G-EN-P - September 2024 61 Chapter 2 Install the Armor PowerFlex Drive Differential (AqB) Single-channel Encoder Wiring Example Differenal (AqB), Single Channel Differenal Encoder Drive Side Motor Side ENCODER CONNECTOR 1. A_SIN- BN 2. A_SIN+ WH /A A 3. B_COS4. B_COS+ /B B 0. SHIELD Outer Shield 5. NC 6. NC C/ C 7. COM 8. POWER BU DGND +UB RD M12 / 8PIN / A-code / Male Differential (AqB) Dual-channel Encoder Wiring Example Differenal (AqB), Dual Channel Differenal Encoder Drive Side Motor Side EK8R Encoder ENCODER CONNECTOR 1. A_SIN- BN 2. A_SIN+ WH 3. B_COS- BK 4. B_COS+ A /B B 0. SHIELD Outer Shield 5. NC 6. NC C/ C 7. COM 8. POWER M12 / 8PIN / A-code / Male 62 PK /A Rockwell Automation Publication 35-UM001G-EN-P - September 2024 BU RD DGND +UB Chapter 2 Install the Armor PowerFlex Drive Hiperface (analog only) Encoder Wiring Example Drive Side Encoder Connector 1. A_Sin2. A_Sin+ 3. B_Cos4. B_Cos+ Motor Side Rotary Encoder Connected with a Shielded, Twisted-pair Cable with an 8-pin Berg Style Connector BN WH BK PK 3. REFSIN 7. +SIN 4. REFCOS 8. +COS 0. Shield 5. NC 6. NC 7. COM 8. Power 6. DATA5. DATA+ BU RD 2. Power COMMON 1. Power M12 / 8-pin / A-code / Plug Rockwell Automation Publication 35-UM001G-EN-P - September 2024 63 Chapter 2 Install the Armor PowerFlex Drive ArmorConnect Media Details of ArmorConnect power media are described in the On-Machine Media for Armor PowerFlex, ArmorStart, and ArmorConnect Products Selection Guide, publication 280PWR-SG001. The ArmorConnect power media offers both three-phase and auxiliary power cable cord set systems, including patchcords, receptacles, tees, reducers and accessories, to be used with the Armor PowerFlex drive. These cable system components facilitate quick connection of Armor PowerFlex drives, reducing installation time. They allow repeatable, consistent connection of the three-phase and auxiliary power to the Armor PowerFlex drive and motor by providing a plug and play environment that also avoids system mis-wiring. IMPORTANT We do not recommend using a tool to tighten the connectors. The connectors should be hand tightened and verified by a torque measurement tool. See the ArmorConnect instructions for the recommended tightening torque. IMPORTANT The UL Listing of the Armor PowerFlex drive requires its mating output motor and input power cable assemblies to be only those assemblies that are specified by the instructions for the controller. By using other cable assemblies, you violate the Listing of the controller, which NFPA 79 prohibits (see 1.5 of NFPA 79 and 110.3(B) of NFPA 70 (NEC). IMPORTANT For proper operation of the Armor PowerFlex drive, the maximum total encoder cable length is 20 m (65.6 ft). IMPORTANT For proper operation of the Armor PowerFlex drive, the maximum total cable length for 24V Auxiliary Power IN, is 20 m (65.6 ft). SHOCK HAZARD: Risk of electrical shock. Do not disconnect or connect power cables under load. ATTENTION: ArmorConnect cables are not intended to be connected or disconnected under load. Connecting or disconnecting ArmorConnect cables under load can result in physical injury or equipment damage, as a result of high make and break currents and potential fault currents. ATTENTION: If you choose to purchase your own cables without connectors and terminate them on site, Rockwell Automation cannot be responsible for failure of the published environmental ratings. ATTENTION: If you install a motor cable that has a connector on one end and floating leads for a field-attachable connector on the other end, use the connector end to attach to the Armor PowerFlex drive. 64 Rockwell Automation Publication 35-UM001G-EN-P - September 2024 Chapter 2 Install the Armor PowerFlex Drive Figure 30 shows example configurations for power, control, and communication media. Figure 30 - Cable System Overview (Armor PowerFlex Drive Standard Version shown) Armor ControlLogix® Controller ArmorStratix™ Ethernet Switch Ethernet cable 8 Ethernet cable 9 EtherNet/IP DLR Main Power Circuit Protection Armor PowerFlex Drive (35E) Frame Size B 1 Input - 0,1 Input - 2,3 Configurable I/O - 0,1 Armor PowerFlex Drive (35E) Frame Size A Input - 0,1 Input - 2,3 Configurable I/O - 0,1 13 13 13 13 13 13 4 7 5 6 Auxiliary/Control Power 10 Ethernet cable 24V DC 120V AC 16 11 4 2 Encoder 11 15 12 12 17 ArmorPower™ Power Supply 24V DC 3-phase Power 2 2 3 - Item Description Example Cat. No. 1 Three-phase power receptacle, round or Three-phase power receptacle, square 280-M35F-Mxx(1) or HARTING® 61 04 201 2753 2 Three-phase power cable, round or Three-phase power cable, square 3 Three-phase power t-port, round or Three-phase power t-port, square 280-PWRM35A-Mxx(1) or HARTING 61 04 202 2953 Lxxx(1) 280-T35 or HARTING 09 12 008 4720 4 5 6 Auxiliary/Control power cable, 4-pin Auxiliary/Control power cable, 4 to 5-pin Auxiliary/Control power cable, 5-pin Auxiliary/Control power t-port, 4-pin 889N-F4AFNM-xx(1) 889L-R5JFN4M-xx(1)(2) 889L-R5JFLE-xx(1)(2) 898N-43PB-N4KF Auxiliary/Control power receptacle, 4-pin 888N-D4AF1-xx(1) 8 9 10 Ethernet patchcord 10/100 MB, D-code to D-code Ethernet patchcord 10/100 MB, X-code to D-code Ethernet patchcord 1 GB, X-code to X-code 1585D-M4TBDM-xx(1) 1585D-E8TGD4E-xx(1) 1585D-E8TGDE-xx(1) 11 Motor cable (with EM brake), 7-pin or 7 not shown 12 Motor receptacle (with EM brake), 7-pin or Motor receptacle (without EM brake), 4-pin 357-PWRM29A-Mxx(1) or 280-PWRM29A-Mxx(1) 284-PWRM29A-Mxx(1) 357-M29M-M05 or 284-M29M-M03 13 I/O cables, standard 889D-R5ACDE-xx(1) 14 120V AC line in cable 889N-F3AFC-F-xx(1) 15 Encoder cable 889D-R8FBDE-xx(1) 16 Encoder receptacle 888D-F8AB3-xx(1) Motor cable (without EM brake), 4-pin (1) xx specifies the available cable lengths. (2) Our current offering of 5-pin, auxiliary power cables and receptacles have an IP66, UL Type 1/12 rating. You must confirm that this rating is acceptable for the intended application. For details, see On-Machine Media for Armor PowerFlex, ArmorStart, and ArmorConnect Products Selection Guide, publication 280PWR-SG001. Rockwell Automation Publication 35-UM001G-EN-P - September 2024 65 Chapter 2 Install the Armor PowerFlex Drive Local Disconnect Behavior The Armor PowerFlex drive has a local, at-motor disconnect switch that is positioned on the front of the unit. The local disconnect meets NFPA compliances, for details, see the Armor PowerFlex AC Drives Specifications Technical Data, publication 35-TD001. The disconnect is a two position maintained switch. Turn right for the On position and turn left for the Off position. The local disconnect removes power from the motor terminals and outputs when in the Off condition. The disconnect switch does not remove the test output power for the safety inputs, but it does remove output power for the bi-polar safety output. When the disconnect switch is in the On position and a short circuit or ground fault event occurs, the Armor PowerFlex drive will fault but the switch handle will NOT change state to a fault position. In this case, you need to manually turn the disconnect switch to the Off position. When the switch is in the Off position, it can be locked in place to act as a lockable maintenance switch. Figure 31 - Local Disconnect in OFF Position ATTENTION: You must verify that hazardous voltages have dissipated before servicing the equipment. For details, see Remove Power Before Servicing the Armor PowerFlex Drive on page 236. The local disconnect may be one of the steps to isolate power, based on regional requirements. Voltage test points enable you to directly measure energy sources including stored energy, that should be verified before maintenance. Unless the quick-connect power cable is marked as a suitable disconnect, disconnecting any power cable before voltage verification is not an acceptable isolation method, because it is still considered under load. The test points allow you to take responsibility and ensure no electrical load before disconnecting the cable. This ensures that internal voltages have dissipated to a safer level that allows maintenance to proceed. 66 Rockwell Automation Publication 35-UM001G-EN-P - September 2024 Chapter 2 Install the Armor PowerFlex Drive Electronic Motor Disconnect The Armor PowerFlex local, at-motor disconnect switch uses a patented design for Electronic Motor Disconnect (EMD). The EMD design provides a reliable means for automatically or manually, disconnecting the motor and Armor PowerFlex drive, from the three-phase power supply. The EMD design can disconnect power in case of fault conditions, device failures, for maintenance, or other shutdown reasons. See TechConnect Document ID QA67224, for information about Armor PowerFlex lockout/tagout. Figure 32 shows a high-level schematic of the EMD control blocks, followed by an explanation of each control block functionality. Figure 32 - EMD Circuit Control Block Explanations • • • • Disconnect Switch – A low voltage (24V DC) Double Pole Single Throw (DPST) switch that provides manual switching control from the three-phase supply. 3-phase Dual Form A Contact Mechanical Relays (wired in series) – The physical means to disconnect the motor and Armor PowerFlex drive from three-phase power. The relays are controlled by the Driver Control block. Driver – Circuit that controls the Mechanical Relays of each phase independently to open or close. The Drive Control Block commands come from the Disconnect Override Control block. Disconnect Override – This circuit controls the Driver Block which commands the relays to open or close. The Disconnect Override Control Block will command the Driver Block to close the Mechanical Relays only if the following conditions are met: - The first contact of the Disconnect Switch is on, providing 24V DC to the Disconnect Override Control Block - The Fault Override Logical Signal from the CPU (Armor PowerFlex firmware) is off (24V signal is high) - The Override Signal from the EnB On-Off Disconnect Detection circuit is off (24V signal is high) The EMD Disconnect Override Block gets a Fault Signal from the CPU indicating that the Armor PowerFlex drive is faulted. When this occurs, the EMD will open. So if the drive sensed a DB Resistor Thermal event, a fault will be created and the EMD will open, which is what an isolating contactor would be used for. Rockwell Automation Publication 35-UM001G-EN-P - September 2024 67 Chapter 2 Install the Armor PowerFlex Drive • 68 On-Off Disconnect Detection – Circuit that monitors the state of each of the contacts of the DPST Disconnect Switch. Each contact is monitored independently by the On-Off Disconnect Detection Block to provide redundant feedback of the state of the Disconnect Switch to the CPU (Armor PowerFlex firmware). If either of the feedback signals detects an open contact in the Disconnect Switch, the PWM Driver will be commanded to disable the gate firing of the Inverter Insulated Gate Bipolar Transistors (IGBTs) so power is cut off to the motor connector. Rockwell Automation Publication 35-UM001G-EN-P - September 2024 Chapter 3 EtherNet/IP Operation Armor PowerFlex drives incorporate the advantages of EtherNet/IP communication for access to configuration, status, and diagnostics. These controllers feature: • • Dual-port embedded switch with 1 GB performance(a) Star Linear and Device Level Ring topologies For more information on EtherNet/IP light-emitting diode (LED) indication status, see EtherNet/IP Status Indicators on page 222. The Armor PowerFlex drive supports: • Ten connected messaging connections • One exclusive owner standard I/O connection • Input and output safety connections for Armor PowerFlex safety drive (35S) IMPORTANT Set the IP Address When applying an Armor PowerFlex drive with a two programmable controller architecture; one for standard connection and the other for safety connection, the safety connection must be made before the standard connection or there will be a connection fault. If the standard connection is made first, the drive enters protected mode and will reject the safety connection causing a fault. There are different methods available for setting the IP address of the Armor PowerFlex drive. You can choose from the following: • Set the IP Address using Rotary Switches • Set the IP Address using the BOOTP/DHCP Server Utility • Set the IP Address using the FactoryTalk Linx Application Set the IP Address using Rotary Switches Use this procedure if you cannot or do not want to use the BOOTP/DHCP tool. There are four rotary switches that are used to set the IP address; one Mode switch and three address switches. The Mode switch is used to set one of the five predefined private IP addresses, except for the last octet. The last octet is set by the three address switches. The Armor PowerFlex drive ships with the Mode switch set to 0 and the three address switches set to 999. This configuration has no IP address set for the drive and DHCP is enabled. (a) Products with EtherNet/IP embedded switch technology have two ports to connect to a linear or DLR network in a single subnet. You cannot use these ports as two Network Interface Cards (NICs) connected to two different subnets. Rockwell Automation Publication 35-UM001G-EN-P - September 2024 69 Chapter 3 EtherNet/IP Operation Remove Front Logic Cover The IP address rotary switches are located under the front logic cover of the Armor PowerFlex drive. With unswitched auxiliary power removed, remove the four screws of the logic cover, then lift it off to access the switches. See Figure 33 and Figure 34. Figure 33 - Logic Cover Removal Figure 34 - IP Address Switches This example shows the rotary address switches set to 123 for an IP Address of 192.168.1.123 FE BYPASS The Mode switch operates as follows: • The Mode switch is read and latched on power-up. • The drive must have power cycled or reset for any Mode switch changes to be recognized. • The Mode switch setting is ignored if the rotary switches address is not within the range of 1…254. Table 6 describes the Mode switch settings when the rotary address switches are set to 1…254. 70 Rockwell Automation Publication 35-UM001G-EN-P - September 2024 Chapter 3 EtherNet/IP Operation Set the Mode switch to one of the predefined IP Address types and then, set the rotary address switches to a value that completes the IP address. Table 6 - IP Address Mode Switch Settings Mode Switch Setting 0 (default) 1 2 3 4 5 6…9 IP Address Type Subnet Mask Rotary Switches Address 1 255.255.255.0 Class C private IP address = 192.168.1.x(1) 2…254 1 255.255.255.0 Class C private IP address = 192.168.6.x(1) 2…254 1 255.255.255.0 Class A private IP address = 10.0.11.x(1) 2…254 100 255.255.0.0 IP address = 136.129.6.x(1) 2…99 or 101…254 1 255.255.0.0 IP address = 11.200.0.x(1) 2…254 1 255.255.0.0 IP address = 11.200.1.x(1) 2…254 The network interface is disabled so the drive cannot communicate on the network. Gateway Address 0.0.0.0 192.168.1.1 0.0.0.0 192.168.6.1 0.0.0.0 10.0.11.1 0.0.0.0 136.129.6.100 0.0.0.0 11.200.0.1 0.0.0.0 11.200.1.1 (1) x = Address switches value. Replace Front Logic Cover After the switches are set, replace the logic cover and tighten the screws 1.37…1.57 N•m (12.13…13.90 lb•in). Figure 35 - Logic Cover Replacement Rockwell Automation Publication 35-UM001G-EN-P - September 2024 71 Chapter 3 EtherNet/IP Operation Example of How to Set the IP Address Switches This is a step-by-step example of how to set the IP address to 192.168.1.123, using the rotary switches: 1. Remove unswitched auxiliary power to the Armor PowerFlex drive. For details, see Auxiliary Power Connections on page 51. 2. Remove the Armor PowerFlex drive’s logic cover. See Figure 33. 3. Set the Mode switch to 0, to select the 192.168.1.x private IP address, as indicated in Table 6. 4. Set the rotary address switches to 123. See Figure 34. IMPORTANT When the switches are set to 192.168.1.1, the subnet mask is set to 255.255.255.0 and the gateway address is set to 0.0.0.0. Switch settings 000 and 255…998 are reserved and cannot be used. 5. Replace the Armor PowerFlex drive’s logic cover. See Figure 35. 6. Re-apply unswitched auxiliary power to the Armor PowerFlex drive. After the Armor PowerFlex drive goes through its boot-up sequence, the IP address is set to 192.168.1.123. 72 Rockwell Automation Publication 35-UM001G-EN-P - September 2024 Chapter 3 EtherNet/IP Operation Set the IP Address using the BOOTP/DHCP Server Utility If the network does not use one of the five private IP addresses that can be set with the Mode switch, the Rockwell Automation BOOTP/DHCP Server Utility (or a third-party DHCP Server) can be used to set the Armor PowerFlex IP address. Before you set the IP address using DHCP, make sure that you have the following information: • MAC ID for the device • Desired IP address for the Armor PowerFlex drive To configure the Armor PowerFlex IP Address using the BOOTP/DHCP utility, after you install and power up the drive, perform the following steps: 1. Run the BOOTP/DHCP software. In the BOOTP/DHCP Request History panel, the hardware (MAC ID) addresses of the devices that are issuing BOOTP/DHCP requests are shown. Figure 36 - BOOTP/DHCP Request History Panel 2. Double-click the hardware (MAC ID) address of the Armor PowerFlex drive that you want to configure. The New Entry dialog box with the Ethernet Address (MAC) of the device is shown. Figure 37 - New Entry Dialog Box 3. Enter the IP address that you want to assign to the device, and click OK. Rockwell Automation Publication 35-UM001G-EN-P - September 2024 73 Chapter 3 EtherNet/IP Operation The device is added to the Relation List, which displays the Ethernet Address (MAC) and the corresponding IP address, host name, and Description (if applicable). Figure 38 - Relation List When the address is displayed in the IP address column in the Request History section, it signifies that the IP address assignment has been made. 4. To assign this configuration to the device: highlight the device in the Relation List panel, and click the Disable BOOTP/DHCP button. When power is cycled to the Armor PowerFlex, it uses the IP Address assigned and will not issue a DHCP request anymore. 5. If desired, DHCP can be enabled using the BOOTP/DHCP Server Utility. To enable DHCP for a device with DHCP disabled: highlight the device in the Relation List, and click the Enable DHCP button. You must have an entry for the device in the Relation List panel to re-enable DHCP. Figure 39 - Enable DHCP Button 74 Rockwell Automation Publication 35-UM001G-EN-P - September 2024 Chapter 3 EtherNet/IP Operation Set the IP Address using the FactoryTalk Linx Application This procedure can only be used when a static IP address for the Armor PowerFlex drive has already been set using a BootP/DHCP server and needs to be changed to a different IP address. IMPORTANT This method cannot be used if the static IP address of the Armor PowerFlex drive has been set using the rotary switches. To change the static IP address of the Armor PowerFlex drive, perform these steps: 1. Launch FactoryTalk Linx and make sure that the IP Address of the Armor PowerFlex drive can be seen. The proper EtherNet driver must have been setup. 2. Once the IP address of the Armor PowerFlex drive appears in the FatoryTalk Linx EtherNet driver, open the advance settings as shown. Rockwell Automation Publication 35-UM001G-EN-P - September 2024 75 Chapter 3 EtherNet/IP Operation 3. In Advanced Settings, check Enable Device Configuration under the General tab and click OK. This allows changing the IP address using FactoryTalk Linx. 4. Right-click the device and choose Device Configuration. 76 Rockwell Automation Publication 35-UM001G-EN-P - September 2024 Chapter 3 EtherNet/IP Operation 5. After the Device Configuration dialog box appears, select the Internet Protocol tab. 6. Click Manually Configure IP Settings (if not already checked) and change the appropriate fields to configure the new IP address. 7. Click Apply to make the changes. 8. Cycle power or reset the device. For more information on how to configure the adapter with the BOOTP/DHCP and FactoryTalk Linx tools, see online help or the EtherNet/IP Network Devices User Manual, publication ENET-UM006. Change IP Address after Safety Device is Configured If you have a safety device configured and want to change the IP address, you need to Reset Ownership. See Reset Ownership on page 97. If you have a running I/O connection (safety or standard), you have to inhibit module in order to perform soft restart via a MSG instruction. See Standard Connection Settings on page 188. Example scenarios: 1. Safety configuration is not deployed. a. Power is not removed. b. Switches are changed to desired IP address. c. Reset command is sent via MSG instruction (CIP Identity reset 0) -> Successful. d. The drive boots with IP address set in step b. 2. Safety configuration is deployed. a. Power is not removed. b. Switches are change to desired IP address. c. Reset command is sent via MSG instruction (CIP Identity reset 0) -> Successful. Rockwell Automation Publication 35-UM001G-EN-P - September 2024 77 Chapter 3 EtherNet/IP Operation d. The drive boots with new IP address but the drive will be in a FAULTED state (Safety recoverable fault). 3. If a safety I/O or standard I/O is running. a. Power is not removed. b. Switches are change to desired IP address. c. Reset command is sent via MSG instruction (CIP Identity reset 0) -> Unsuccessful as there is a running I/O connection. Device Level Ring Device Level Ring (DLR) is an EtherNet/IP protocol that is defined by the Open DeviceNet Vendors Association (ODVA). DLR provides a means to detect, manage, and recover from single faults in a ring-based network. A DLR network includes the following types of ring nodes. Table 7 - DLR Nodes Node Ring supervisor Ring participants Redundant gateways (optional) Description A ring supervisor provides these functions: • Manages traffic on the DLR network • Collects diagnostic information for the network A DLR network requires at least one node to be configured as ring supervisor. By default, the supervisor function is disabled on supervisor-capable devices. Ring participants provide these functions: • Process data that is transmitted over the network. • Pass on the data to the next node on the network. • Report fault locations to the active ring supervisor. When a fault occurs on the DLR network, ring participants reconfigure themselves and relearn the network topology. Redundant gateways are multiple switches that are connected to a single DLR network and also connected together through the rest of the network. Redundant gateways provide DLR network resiliency to the rest of the network. Depending on their firmware capabilities, both devices and switches can operate as supervisors or ring nodes on a DLR network. Only switches can operate as redundant gateways. See Figure 40 on page 79 for an example of a DLR network. IMPORTANT The Armor PowerFlex drive cannot be configured as a ring supervisor. For more information about DLR, see the EtherNet/IP Device Level Ring Application Technique, publication ENET-AT007. 78 Rockwell Automation Publication 35-UM001G-EN-P - September 2024 Chapter 3 EtherNet/IP Operation Figure 40 - Armor PowerFlex Drive in a DLR Configuration 1738-AENTR 1738 I/O Modules 1783-ETAP Workstation 1783-ETAP PanelView Terminal Armor PowerFlex Drive Device Level Ring 1783-ETAP 1734-AENTR 1734 I/O Modules 1756-EN2TR 1756 I/O Modules Distributed I/O 1769-L23Ex 1756-EN2T 1756 I/O Modules 1769-L3xE 1794-AENT 1794 I/O PowerFlex Drive 1734-AENT Workstation It is recommended that no more than 50 nodes are on a single DLR. If your application requires more than 50 nodes, it is recommended that the DLR networks be segmented. With smaller networks: • There is better management of traffic on the network. • The networks are easier to maintain. • There is a lower likelihood of multiple faults. Rockwell Automation Publication 35-UM001G-EN-P - September 2024 79 Chapter 3 EtherNet/IP Operation Protected Operations Mode To maintain the secure operation of your drive, operations that can disrupt drive operation are restricted based on its operating mode. This drive is in protected mode when: there are standard or safety I/O connections, the drive is running. When there is a Standard I/O connection, or the drive is running, the following features are disabled: • Configuration of standard control attributes • Configuration of Network Attributes • Enabling/Disabling Physical Ports • Remote Resets • Security Configurations (except to preexisting configuration over previously made secure connection) • Firmware Updates When there is a Safety I/O connection, remote reset and firmware updates are disabled, along with reconfiguration of safety parameters. This means that some Armor PowerFlex configuration changes are not allowed under certain conditions, so that the drive operation is not disturbed. Safety configurations are allowed when there is a standard I/O connection to support commissioning efforts. If an attempt is made, a device state conflict error is reported. 80 Rockwell Automation Publication 35-UM001G-EN-P - September 2024 Chapter 3 Ethernet Communication Troubleshooting EtherNet/IP Operation The EtherNet/IP communication module can experience intermittent network connectivity due to these conditions: • Duplex mismatch • Electrical noise that is induced into a cable or results from a Logix/switch ground potential difference • Bad hardware, such as a cable or switch port To help troubleshoot the EtherNet/IP network, you must use a managed switch. Here are the important features in a managed switch: • Internet Group Multicast Protocol (IGMP) snooping • Support for Virtual Local Area Networks (VLAN) • Port mirroring IMPORTANT Use a switch that is equipped with wire-speed switching fabric. The switch fabric is a measure of the maximum traffic that a switch can handle without dropping a packet and without storing a packet in memory. Wire-speed switching fabric refers to a switch that can handle the maximum data rate of the network on each of its ports. Switches are typically rated in Gbps. For a 10-port switch connected to EtherNet/IP products, the maximum data rate that is needed, is typically 100...200 MB/s. Therefore, a 10-port-switch that is rated at least 1 GB/s is adequate for an EtherNet/IP application. For more information on EtherNet/IP networks, see these resources: Table 8 - Resources for EtherNet/IP Network Information Publication Troubleshoot EtherNet/IP Networks Application Technique, publication ENET-AT003 EtherNet/IP Device Level Ring Application Technique, publication ENET-AT007 Ethernet Design Considerations Reference Manual, publication ENET-RM002 Description Describes troubleshooting techniques for Integrated Architecture products on EtherNet/IP networks. Describes DLR topologies, configuration considerations, and diagnostic methods, including how to monitor your EtherNet/IP network. Describes basic Ethernet concepts, infrastructure components, and infrastructure features. Rockwell Automation Publication 35-UM001G-EN-P - September 2024 81 Chapter 3 EtherNet/IP Operation Notes: 82 Rockwell Automation Publication 35-UM001G-EN-P - September 2024 Chapter 4 Keypad Operation The Armor PowerFlex drive has a front panel keypad with four buttons to allow user input. • LOCAL/AUTO, F0 • FWD/REV, F1 • JOG, F2 • FAULT CLEAR The keypad also has status indicator LEDs, which indicate the mode that the keypad is in and the status of the buttons. Table 9 - Keypad Button Operation Button Fault Clear Local/Auto Description • Pressing Fault Clear can clear all existing non-critical standard faults. (Clearing all faults might require additional actions, such as cycling main input power.) • It does not clear any alarms. • Press this button to toggle between Local and Auto modes. The default mode is Auto. • Local is a manual override mode that provides local control via the Forward/Reverse and Jog keypad buttons. • Auto is for control of the drive where all reference and sequencing commands come from a network connection. When in Auto mode, the Forward/Reverse and Jog keypad buttons are not operational. Status Indicator Mode — — Local/Auto— Red Local Local/Auto— Green Auto Fwd/Rev — Steady green Local mode forward direction mode • When in Local mode, press this button to toggle between forward and reverse direction for Fwd/Rev — Steady red Local reverse direction Forward/Reverse running the motor. Forward is the default direction, which is set at power-up. • Direction is maintained when switching between Local and Auto modes. Local mode Fwd/Rev — Blink Jog button pressed Fwd/Rev — Off Auto mode Fwd/Rev — Jog forward direction • When in Local mode, pressing and holding the Jog button jogs the motor. Blink green Jog • The Fwd/Rev blinks when the drive is modulating. Fwd/Rev — Blink red Jog reverse direction Function Mode — • To enable Function mode, see Temporarily Disable Keypad Motor Control on page 85. Function mode • In Function mode, the three buttons provide generic inputs whose function can be set by using Steady amber program logic. Pressing the F0, F1, or F2 button has no direct effect on product behavior. The F0key is pressed or, F0, F1, F2 — button state is reported to let user-defined logic take action based on the state of the button. F1 key is pressed or, Function Mode The buttons are momentary, meaning that they are active when pressed and de-activated when Steady amber F2 key is pressed (F0, F1, F2) released. F0key is not pressed or, F1 • When pressed, the button state reported to the network is 1. When released, the button state F0, F1, F2 — Off key is not pressed or, F2 reported to the network is 0. key is not pressed IMPORTANT You cannot use the LOCAL/AUTO button to change the mode while the drive is running. Rockwell Automation Publication 35-UM001G-EN-P - September 2024 83 Chapter 4 Keypad Operation One button press is recognized at a time. To switch from jogging forward to jogging reverse, first remove the jog, press reverse, and then reassert the jog. This does not mean that the motor must be at rest. Keypad Modes The keypad operates in three different modes: Auto, Local, and Function. The keypad is used for motor control and will only block network motor control commands, while in Local mode. • Auto – Motor control via the keypad is enabled, but not active. Local control from the embedded keypad is ignored. The Armor PowerFlex drive is only controlled via the EtherNet network. • Local – Motor control via the keypad is enabled and it is active. The Armor PowerFlex drive is controlled from the embedded keypad only. If the unit is connected to a network, most commands are ignored. • A network stop command will take precedence over the keypad when set to local mode. The network stop command will prevent local jog via the keypad. Function – Motor control via the keypad is disabled, the keypad button state is still reported. The F0, F1, and F1 buttons are used as inputs and not for control. Local/Auto (Local Motor Control) Modes Operation Local and Auto modes are used when the keypad is enabled for motor control operation. In these modes, the three keypad buttons have a specific function: • LOCAL/AUTO toggles between Auto or Local modes with the status indicator displaying the current mode (local is default). The drive must not be running to use the button to switch modes in Auto mode, the Forward/Reverse and Jog buttons don't do anything • Forward/Reverse toggles between directions in Local mode. The indicator displays the current direction (forward is default). At power-up, the keypad direction is set to forward. The direction is maintained when switching between LOCAL/AUTO mode. • Pressing Jog causes the motor to move at the jog reference velocity, in Local mode. The default jog velocity is 10 rev/s (20 Hz). Function Mode Operation When Function mode is selected (see Temporarily Disable Keypad Motor Control on page 85), all three buttons become generic inputs whose function can be set by using programmable controller logic. When the keypad mode is Function, pressing the keypad buttons F0, F1, and F2 have no direct impact on product behavior. In this mode, the button state is reported to allow user-defined logic to take action based on the button state. The F0, F1, and F2 LEDs indicate if a button is being pressed. Fault Clear Button Operation 84 When the Fault Clear button is pressed, any faults currently unacknowledged in the product are acknowledged. You cannot disable or change the function of the Clear Faults button. Rockwell Automation Publication 35-UM001G-EN-P - September 2024 Chapter 4 Temporarily Disable Keypad Motor Control Keypad Operation Keypad motor control operation can be temporarily disabled by two different methods. • Datalink • Message Instruction Datalink The keypad can be disabled by using the output datalink, Disable predefined Keypad Functions. For datalink configuration details, see Configure Datalinks on page 159. Message Instruction To temporarily disable the keypad motor control operation, a MSG instruction targeting attribute 2, (Inhibit) of the Motor Control Source object, can be used. Set this attribute to 1 (true) to disable keypad motor control operation. Table 10 shows the message instruction parameter needed to temporarily disable the keypad control. Table 10 - Keypad Control: MSG Parameter Service Code Class Instance Attribute Value 0x10 0x41c 1 2 Value BOOL Description Set attribute single Motor control source Keypad Inhibit 0 = Source not inhibited (Keypad active) 1 = Source inhibited (Keypad disabled) This configuration allows you to temporarily use Local mode of the keypad to perform maintenance tasks when needed, while disabling use of the keypad for motor control during normal operation. IMPORTANT The value of the Inhibit attribute is reset to 0 (not inhibited, keypad can be used for motor control) when the drive has power cycled. If it is important that the keypad be inhibited in the application, logic should be added to resend the inhibit message instruction after a power cycle, or simply resend the inhibit message instruction, periodically. Rockwell Automation Publication 35-UM001G-EN-P - September 2024 85 Chapter 4 Keypad Operation Keypad Actions in Local and Function Modes Table 11 and Table 12 show what actions occur for Local and Function modes and list what LEDs are illuminated, including their color. In Disabled mode, no buttons are active and all LEDs are Off. Table 11 - Local Mode Keypad Actions LOCAL/AUTO Button AUTO selected LOCAL selected Drive is remotely controlled. Keypad F/R and JOG buttons are not active. All reference and Drive is in local control. Allows use of the JOG sequencing commands come from a network and F/R buttons connection / logic controller. LOCAL Mode Mode LEDs Top: Green Bottom: Off LOCAL/AUTO LED Red Green Fwd/Rev LED Off Fwd — Green Rev — Red Not active Selects JOG direction Fwd/Rev Button JOG Button pressed Not active JOG Button not selected Not active Fwd/Rev LED — Blinks while JOG is pressed Green — Forward JOG Red — Reverse JOG (the drive jogs while the JOG button is pressed) Fwd/Rev LED — Steady (no blink) based on selected direction color F0 LED Amber LED — Off Amber LED — Off F1 LED Amber LED — Off Amber LED — Off F2 LED Amber LED — Off Amber LED — Off Table 12 - Function Mode Keypad Actions and Status Indicators FUNCTION mode Mode LEDs Top: Off Bottom: Amber All reference All reference All reference All reference All reference All reference and and and and and and commands commands commands commands commands commands come from the come from the come from the come from the come from the come from the network. network. network. network. network. network. LOCAL/AUTO Mode LED Off Off Off Off Off Off Fwd/Rev LED Off Off Off Off Off Off Amber LED — On Amber LED — Off Amber LED — Off Amber LED — Off Amber LED — Off Amber LED — Off Amber LED — Off Amber LED — On Amber LED — Off Amber LED — Off Amber LED — Off Amber LED — Off Amber LED — Off Amber LED — Off Amber LED — On Amber LED — Off Amber LED — Off Amber LED — Off F0 LED F1 LED F2 LED 86 LOCAL/AUTO - F0 Button Fwd/Rev - F1 Button JOG – F2 Button F0 selected F0 unselected F1 selected F1 unselected F2 selected F2 unselected Network reads Network reads Network reads Network reads Network reads Network reads F0 state = ‘1’ F0 state = ‘0’ F1 state = ‘1’ F1 state = ‘0’ F2 state = ‘1’ F2 state = ‘0’ Rockwell Automation Publication 35-UM001G-EN-P - September 2024 Chapter 5 Standard and Configurable I/O Operation All Armor PowerFlex drives include four standard inputs and two standard configurable I/Os. These inputs and outputs are used with sensors and actuators respectively, for monitoring and controlling the application process. The Armor PowerFlex safety drive (35S) includes safety I/Os: two test outputs, four safety inputs, and one bipolar safety output. The four safety inputs share the two test outputs (two safety inputs per test output). See Chapter 6 for safety I/O details. Standard I/O Operation The Armor PowerFlex drives include four inputs that are single keyed (two inputs per connector) and sourced from control power. The inputs use two M12 connectors. Each input has an light-emitting diode (LED) status indication (See I/O Status Indicators on page 221 for details). They are configurable as sinking or sourcing (See Configure Test Outputs on page 198 for configuration details). Short-circuit protection: The maximum sourcing sensor power is 300 mA for all discrete inputs. Therefore if all six are inputs, a maximum of 50 mA is allowed per input. Or for any single input, the full 300 mA can be sourced. If maximum sourcing power is exceeded, a fault is generated. You can set an On to Off and Off to On, filter time in the programming software. This setting helps prevent rapid changes of input data due to contact bounce. Each I/O point has a status LED see I/O Status Indicators on page 221 for details. Rockwell Automation Publication 35-UM001G-EN-P - September 2024 87 Chapter 5 Standard and Configurable I/O Operation Standard Input Internal Wiring Diagram Armor PowerFlex Drive Internal Circuitry Field Device Connection Unswitched_24V DC +24V DC VCC_3V3 Input 1 In1 Circuitry Common µC VCC_3V3 Input 0 In0 Circuitry Chassis M12 5-Pin Connector Standard Input Wiring Examples Connected Devices Connection Schematic Diagram Reset switch Connect the reset switch between +24V Unswitched Sensor Power and Input 1 Pin 1:+24V unswitched (sensor) power Pin 2: Input 1 Pin 3: Input Common Pin 4: Input 0 Pin 5: Chassis (PE) 1 2 5 4 Dual input configuration Connect the LED between 24V and Input 1 and connect the reset switch between 24V and Input 0 Pin 1:+24V unswitched (sensor) power Pin 2: Input 1 Pin 3: Input Common Pin 4: Input 0 Pin 5: Chassis (PE) 3 1 4 88 Rockwell Automation Publication 35-UM001G-EN-P - September 2024 2 5 3 Chapter 5 Configurable I/O Operation Standard and Configurable I/O Operation The Armor PowerFlex drives have two configurable I/O points that are self-configurable as either an input or output, based on the electrical connection used. By default, the I/O points are configured as inputs. The two I/O points are sourced from switched auxiliary power. The two I/O points use one single-keyed two M12 connector. Each I/O has an LED status indication (See I/O Status Indicators on page 221 for details). The self-configuring I/O points are named I/O0 and I/O1. Turning a self-configuring I/O point ON via the Output Tag devicename.O.IO_0 or devicename.O.IO_1, makes it behave as an output. See Table 78 on page 207. IMPORTANT To operate properly, standard outputs require a minimum load of 10 mA, otherwise an over/under current error will occur. The Input Tag devicename:I.IO_0 or devicename.I.IO_1 value reflects the state of a connected input device, if one is connected, or the output state, if the point is being used to drive an output device. You must confirm that the Discrete Output Point output value is not accidentally set to 1 if the point is being used as an input. • If an I/O point is to be an output, dedicate that point as an output with a wired load and energize it through a control program. • Energized outputs show an associated active input that can be used as a feedback mechanism to verify that the output is on. • If an I/O point is to be an input, wire the input device as normal and leave the associated output de-energized at all times. When a fault occurs, standard outputs (the self-configuring I/O points) will be set to a known state based on their configured fault action. Configured Fault Actions • • • Connection Idle (Controller Run -> Program Transition) Action Connection Fault Action Product Fault Action To configure the fault action for the configurable I/O, see Configure Standard I/O Points on page 190. Rockwell Automation Publication 35-UM001G-EN-P - September 2024 89 Chapter 5 Standard and Configurable I/O Operation Configurable I/O Internal Wiring Diagram (Output) Armor PowerFlex Drive Internal Circuitry Field Device Connection Switched_24VDC No connection VCC_3V3 Switched_24V DC Output 1 Out1 Circuitry Common µC Output 0 Out0 Circuitry VCC_3V3 Chassis Switched_24V DC M12 5-Pin Connector Standard Output Wiring Examples Connected Devices Connection Schematic Diagram Output drives LED (I/O configured as output) Connect the LED between Input/Output 1 and Common Pin 1:+24V unswitched (sensor) power Pin 2: Input/Output 1 Pin 3: Input Common Pin 4: Input/Output 0 Pin 5: Chassis (PE) 1 4 Connect the first LED between Input/Output 1 Pin 1:+24V unswitched (sensor) power and Common Pin 2: Input/Output 1 Outputs drive LEDs (Both of the I/Os Connect the are configured as second LED outputs) between Input/Output 0 and Common 2 5 3 1 Pin 3: Input Common Pin 4: Input/Output 0 Pin 5: Chassis (PE) 2 5 4 3 Standard I/O Wiring Example Connected Devices Connection Output: Connect the LED between Input/Output 1 and Common Output drives LED and Input as Connect the reset reset switch switch between Input/Output 0 and +24V Unswitched Sensor Power 90 Schematic Diagram Input Pin 1:+24V unswitched (sensor) power Pin 2: Input/Output 1 Pin 3: Input Common Pin 4: Input/Output 0 Pin 5: Chassis (PE) Rockwell Automation Publication 35-UM001G-EN-P - September 2024 Output 1 2 5 4 3 Chapter 6 Safety Functions This chapter only applies to the Armor PowerFlex safety version (35S) used in a safety application. If you are using an Armor PowerFlex standard version (35E), this chapter does not apply to you. The Armor PowerFlex safety version provides hard-wired Safe Torque Off (STO), integrated Safe Torque Off (STO), integrated drive-based Safe Stop 1 functions, Safe Brake Control (SBC), and integrated controller-based Safe Monitor functions, capability. Table 13 - Integrated Safety Functions and Compatible Controllers Integrated Safety Over the EtherNet/IP Network Safety Function Drive-based stop functions • Timed Safe Stop 1 (SS1) • Monitored Safe Stop 1 (SS1)(1) • Safe Brake Control (SBC) Controller-based stop functions • Monitored Safe Stop 1 (SS1)(1) • Safe Brake Control (SBC) Controller-based monitor functions Safety feedback function Integrated STO mode Minimum Controller Required (Versions 32.xx…34.xx and 36.xx — not compatible with 35.xx) • GuardLogix 5580 • Safely Limited Speed (SLS)(1) • Compact GuardLogix 5380 • Safely Limited Position (SLP)(1) • Safe Direction (SDI)(1) Safety Feedback Interface (SFX)(1) Safe Torque Off (STO) (1) Monitored safety functions require an encoder to be configured in the safety configuration. Table 14 - Hardwired Safety Functions and Compatible Controllers Hardwired Safety — No Safety Connection Safety Function Hardwired STO mode IMPORTANT Safe Torque Off (STO) Minimum Controller Required for Standard Connection (Versions 32.xx…34.xx and 36.xx — not compatible with 35.xx) • ControlLogix 5570 or 5580 • Armor ControlLogix 5570 • GuardLogix 5570 or 5580 • Armor GuardLogix 5370 • CompactLogix 5370 or 5580 • Armor CompactLogix 5370 includes GuardLogix variants • Compact GuardLogix 5370 or 5580 The functional safety part of the product does not need any maintenance (apart from proof testing, if applicable). For the functional safety part of the product, no spare parts are available and no repair is possible or intended by the user. If there is a permanent fault, the device has to be taken out of use and replaced by another device. Rockwell Automation Publication 35-UM001G-EN-P - September 2024 91 Chapter 6 Safety Functions Safety Considerations ATTENTION: The drive is suitable for performing mechanical work on the drive train or affected area of a machine only. It does not provide electrical safety. ATTENTION: The drive does not remove dangerous voltages at the drive output. Before performing any electrical work on the drive or motor, turn off the input power to the drive, and follow all safety procedures. ATTENTION: Failure to maintain the specified ambient temperature can result in a failure of the safety function. ATTENTION: Personnel responsible for the application of safety-related programmable electronic systems (PES) must be aware of the safety requirements in the application of the system and must be trained in use of the system. ATTENTION: When designing your system, consider how various personnel can interact with the machine. Additional safeguard devices can be required for your specific application. ATTENTION: In circumstances where external influences (for example, suspended loads that can fall) are present, additional measures (for example, mechanical brakes) can be necessary to help prevent any hazard. The system operator is responsible for the following: • Setup, safety rating, and validation of any sensors or actuators connected to the system • Completion of a machine-level risk assessment and reassess the system anytime a change is made • Certification of the machine to the desired ISO 13849-1 performance level or EN/IEC 62061 SIL CL level • Project management and proof testing in accordance with ISO 13849-1 • Programming the application software and the drive configurations in accordance with the information in this manual • Access control to the system • Analyzing all configuration settings and choosing the proper setting to achieve the required safety rating • Validation and documentation of all safety functions used • Performance of necessary proof tests and periodic safety checks Stop Category Definitions There are two stop categories that apply to Armor PowerFlex drives: • Stop Category 0 is achieved with immediate removal of power to the machine actuators, which results in an uncontrolled coast-to-stop. An STO accomplishes a Stop Category 0 stop. • Stop Category 1 is achieved with a Ramp to Stop followed with immediate removal of power to the machine actuators. An SS1 with STO accomplishes a Stop Category 1 stop. IMPORTANT 92 When designing the machine application, consider the timing and distance for a coast-to-stop (Stop Category 0 or Safe Torque Off). For more information on stop categories and Safe Torque Off, see EN 60204-1 and EN/IEC 61800-5-2. Rockwell Automation Publication 35-UM001G-EN-P - September 2024 Chapter 6 Performance Level and Safety Integrity Level Safety Functions For safety-related control systems, Performance Level (PL), according to ISO 13849-1, and Safety Integrity Level (SIL), according to IEC 61508 and IEC 62061, include a rating of the systems ability to perform its safety functions. All safety-related components of the control system must be included in both a risk assessment and the determination of the achieved levels. See the ISO 13849-1, IEC 61508, and IEC 62061 standards for complete information on requirements for PL and SIL determination. See rok.auto/certifications for product certifications. Proof Tests IEC 61508 requires you to perform various proof tests of the equipment that is issued in the system. Proof tests are performed at user-defined times. For example, proof tests can be once a year, once every 15 years, or whatever time frame is appropriate. The Armor PowerFlex drive has a useful life of 20 years; no proof test is required. Other components of the system, such as safety I/O devices, sensors, and actuators, can have different useful life times. IMPORTANT PFD and PFH Definitions The time frame for the proof test interval depends on the specific application. 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 safetyrelated 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 the order-ofmagnitude ranges of its average probability of failure to perform its safety function on demand or, simply, the average probability of a dangerous 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 (PFH) per hour. For redundant parts of a PDS (SR) which cannot be tested without disrupting the application in which the PDS (SR) is used (machine or plant) and where no justifiable technical solution can be implemented, the following maximum diagnostic test intervals can be considered as acceptable. See Table 15. Table 15 - Maximum Diagnostic Test Intervals To achieve the listed safety rating Maximum STO demand interval SIL 3/Category 4, PLe one STO operation per day SIL 3/Category 3, PLe one STO operation per three months SIL 2/Category 3, PLd one STO operation per year Rockwell Automation Publication 35-UM001G-EN-P - September 2024 93 Chapter 6 Safety Functions Safety Data for Armor PowerFlex Drives The following sections list safety data for Hardwired STO and Integrated STO and Safety Functions. Table 16 - PFD and PFH for Armor PowerFlex Drives Hardwired STO Attribute Value PFD(average) 2.65 E-04 PFH (1/hour) 3.04 E-09 SIL 3 PL e Category 4 MTTFd years 139.7 (high) DCavg% 97.2% (medium) HFT (hardware fault tolerance) 1 Mission time 20 years Safety Data for Integrated STO and Integrated Safety Functions These PFH calculations are based on the equations from Part 6 of EN 61508 and show worstcase values. Table 17 - PFD and PFH for Armor PowerFlex Drives Integrated STO and Timed SS1 Attribute Value PFD(average) 1.56 E-4 PFH (1/hour) 1.76 E-9 SIL 3 PL e Category 4 MTTFd years 171.3 (high) DCavg% 97.7% (medium) HFT 1 Mission time 20 years Table 18 provides PFH values to add for safety functions that use the safety I/O provided on the Armor PowerFlex drive. Table 18 - PFD or PFH to Add When Safety Functions Use Safety I/O Attribute Single Channel Safety I/O Dual Channel Safety I/O PFD (average) 6.64 E-4 1.12 E-4 PFH (1/hour) 7.58 E-9 1.28 E-9 SIL 2 3 PL d e Category 2 4 MTTFd years 760.3 757.6 DCavg% 95% 95% HFT 0 1 Mission time 20 years 20 years IMPORTANT 94 Single channel safety I/O is only certified for use in functional safety applications with process safety times greater than or equal to 300 ms; or applications with demand rates for both input and output, less than or equal to 1 demand per 30 s. Rockwell Automation Publication 35-UM001G-EN-P - September 2024 Chapter 6 IMPORTANT Safety Functions If single channel safety I/O is used, pulse testing (external pulse testing for safety inputs, pulse testing for safety outputs) MUST be enabled on the single channel I/O points. Safety Data for Safety Functions with Safety Feedback Table 19 provides PFDavg and PFH values to add to the PFDavg and PFH values from Table 17 or Table 18 for safety functions that require safe encoder feedback. Safety functions that use safe encoder feedback include: drive based Monitored Safe Stop 1 and controller-based safety functions SS1, SLS, SLP, and SDI. In general, the PFDavg and PFH values from Table 19 should be added to Table 17 and Table 18 when Safety Instance is set to ‘Single Feedback Monitoring’. Table 19 - PFD or PFH to Add When Safety Functions Use Safety Feedback Attribute PFD (average) PFH (1/hour) SIL PL Category MTTFd years DCavg% HFT Mission time Single Encoder Feedback IMPORTANT Achievable safety rating depends on each system component. For Safe Feedback, the safety rating of the selected encoders could limit the safety rating of the system. 2.88 E-5 3.29 E-10 2 d 3 2154.3 97.3% 1 20 years Safety Reaction Time The safety reaction time is the length of time from a safety-related event as input to the system until the system is in the safe state. Table 20 shows the safety reaction time from an input signal condition that triggers a safe stop, to the initiation of the configured Stop Type. For details on how to calculate system reaction times with GuardLogix controllers, see the GuardLogix Controller Systems Safety Reference Manuals that are listed in the Additional Resources on page 12. Table 20 - Safety Reaction Time Function Hardwired STO Integrated STO Safety Output Reaction Time (excludes connection reaction time) 12 ms 10 ms 10 ms A number of factors influence the safety reaction time, including the configuration of the safety I/O on your device and the configuration of your safety controller. These factors include: • Safety Input On to Off and Off to On delay settings, if applicable • Safety Input Connection Reaction Time Limit settings • Safety controller Safety Task Period and Watchdog settings • Produced and consumed safety Connection Reaction Time Limit settings • Safety Output Connection Reaction Time Limit settings Rockwell Automation Publication 35-UM001G-EN-P - September 2024 95 Chapter 6 Safety Functions See Safety Input and Output Connection Settings (safety variants only) on page 189, for information on how to configure these settings. For details on reaction time calculation of your safety system, see Reaction Times in the GuardLogix Controller Systems Safety Reference Manual, for your safety programmable controller. These manuals are listed in the Additional Resources on page 12. Spurious Trip Rate Table 21 shows the Spurious Trip Rate (STR) and Mean Time to Failure Spurious (MTTF Spurious) values, calculated according to the ISA TR-84 method. Table 21 - STR and MTTF Spurious Rates Attribute Value Spurious Trip Rate (per hour) 6.61 E-6 MTTF Spurious (years) 1.73 E+1 Contact Information If Safety Failure Occurs If you experience a failure with any safety-certified device, contact your local Allen-Bradley distributor to request any of these actions: • Return the device to Rockwell Automation so the failure is appropriately logged for the catalog number that is affected and a record is made of the failure. • Request a failure analysis (if necessary) to determine the probable cause of the failure. Safe Torque Off Function The TÜV Rheinland group has approved Armor PowerFlex drives with hardwired and integrated Safe Torque Off (STO) for use in safety-related applications up to ISO 13849-1 Performance Level e (PLe), SIL CL 3 per IEC 61508, IEC 61800-5-2, and EN/IEC 62061, in which removing the motion-producing power is considered to be the safe state. For product certifications currently available from Rockwell Automation, go to rok.auto/ certifications. All components in the system must be chosen and applied correctly to achieve the desired level of operator safeguarding. Description of Operation The Armor PowerFlex STO circuit is designed to turn off all output-power transistors when the STO function is requested. You can use the Armor PowerFlex STO circuit in combination with other safety devices to achieve a Stop Category 0 stop as described in Stop Category Definition for STO on page 97, and protection-against-restart as specified in IEC 60204-1. ATTENTION: When designing your system, consider how various personnel can interact with the machine. Additional safeguard devices can be required for your specific application. ATTENTION: If there is a failure of two output IGBTs in the Armor PowerFlex drive, the Armor PowerFlex drive can provide energy for up to 180° of rotation in a 2-pole motor before torque production in the motor ceases. The STO feature provides a method, with a sufficiently low probability of failure, to force the power-transistor control signals to a disabled state. When disabled, or anytime power is removed from the safety enable inputs, all drive output-power transistors are released from the On state. This results in a condition where the drive performs a Category 0 Stop (see Stop Category Definition for STO on page 97). Disabling the power transistor output does not provide physical isolation of the electrical output that is required for some applications. See Safe Brake Control Function on page 116 for information on how to use a mechanical brake with the drive. 96 Rockwell Automation Publication 35-UM001G-EN-P - September 2024 Chapter 6 Safety Functions ATTENTION: When STO is demanded, the motor output provides mechanical isolation of the electrical output that is required for some applications. ATTENTION: In circumstances where external influences (for example, falling of suspended loads) are present, additional measures (for example, mechanical brakes) may be necessary to help prevent any hazard. Stop Category Definition for STO Stop Category 0 as defined in IEC 60204 or Safe Torque Off as defined by IEC 61800-5-2 is achieved with immediate removal of motion-producing power to the actuator. IMPORTANT If there is a malfunction, the most likely stop category is Stop Category 0. When designing the machine application, timing and distance must be considered for a coast-to-stop. For more information regarding stop categories, see IEC 60204-1. Reset Ownership After the integrated safety connection configuration is applied to the drive at least once, you can restore the Armor PowerFlex drive to the out-of-box state by resetting ownership in the Logix Designer application, while online. When you reset the Armor PowerFlex drive, all configuration settings, including standard and safety I/O configurations are returned to their out-of-box settings. Resetting Ownership using the Logix Designer application, requires that the Module Connection is inhibited. Follow these steps to inhibit the module connection: 1. Right-click the device and click Properties. 2. Click Connection. 3. Check the Inhibit Module checkbox. 4. Click Apply and then OK. Rockwell Automation Publication 35-UM001G-EN-P - September 2024 97 Chapter 6 Safety Functions Follow these steps to reset the device to its out-of-box configuration when online. 1. Right-click the module and choose Properties. 2. Click Safety Configuration. 3. Click Reset Ownership. IMPORTANT During Reset Ownership, the Logix Designer application is locked and you cannot perform any other actions. 4. Click Continue. The Logix Designer application is locked until the reset is completed. Out-of-Box State Out-of-Box is the state in which the Armor PowerFlex drive is delivered from the factory. All configuration settings including standard and safety I/O configurations, are returned to factory default values. In the Out-of-Box state, the drive is in Hardwired STO mode, which means it is ready for hardwired connections to the safety I/O. See Description of Operation on page 96. 98 Rockwell Automation Publication 35-UM001G-EN-P - September 2024 Chapter 6 Safety Functions Reset to Out-of-box State You can reset the Armor PowerFlex drive to the out-of-box state in two ways: • By resetting ownership via the Logix Designer application. See Reset Ownership • By setting the IP address switches to 888 using the following procedure: a. Remove power from the product. Wait for it to power down. b. Set the network address switches to 888. See Set the IP Address on page 69 for instructions on how to set the IP address. The IP Mode switch is ignored because the network address switch setting of 888 is not within the range of 1…254. c. Apply power to the product. d. Wait for 60 seconds. e. Remove power from the product. Wait for it to power down. f. Set the network address switches to 1 to 254 or 999. g. Reapply power to the product. The product’s configuration settings have been restored to their factory default values. IMPORTANT Only authorized personnel should attempt to reset ownership. The safety connection must be inhibited before the reset is attempted. If any active connection is detected, the safety reset is rejected. Recognize Out-of-box State Using a Message Instruction A message instruction can be used to query the Safety Supervisor Object to determine if the device is in the out-of-box state. The safety supervisor state provides information on the state of the integrated safety connection and the mode of operation. There is only one safety supervisor object per drive module. Table 22 shows the message instruction parameter that is needed to query the Safety Supervisor Object. Table 23 shows the possible response values and their relation to the safety connection. For a message instruction example, see Appendix B on page 251. Table 22 - Safety Supervisor State: MSG Parameter Service Code Class Instance Attribute Data Type Value 0x0E 0x39 1 0x0B 11 (decimal) SINT Description Get attribute single Safety supervisor Revision Device status Short integer Table 23 - Safety Supervisor States Value 1 2 Display Text Testing Idle 3 Test Flt 4 5 6 7 8 51 52 Executing Abort Critical Flt Configuring Waiting Wait w Trq Exec w Trq Definition Device is performing test diagnostics No active connections A fault has occurred while executing test diagnostics Normal running state A major recoverable fault has occurred A critical fault has occurred Transition state Out-of-box state Out-of-box state STO bypass state Rockwell Automation Publication 35-UM001G-EN-P - September 2024 99 Chapter 6 Safety Functions STO Bypass Operation To support commissioning of the product, a STO bypass plug may be used to enable torque. The STO bypass plug can be used on either pair of inputs to enable torque. Figure 41 - Hardwired STO - Safety Bypass Plug 2 3 IMPORTANT 5 1 4 Pin 1: Test Output 1 Pin 2: Safety Input 1 Pin 3: Input Common Pin 4: Safety Input 0 Pin 5: Test Output 0 To use the 35S drive in an application without safety or to bypass the STO feature while commissioning or testing the drive, the drive must be in Hardwired mode and either safety input pair must be wired to enable torque. The safety bypass jumper plug can be used for this purpose. ATTENTION: If you bypass the STO feature, the safety system permits motor torque that could result in unintended motion. Use additional preventive measures to maintain the safety integrity of the machinery. Hardwired Safe Torque Off Function Armor PowerFlex safety drives (35S) are configured for Hardwired Safe Torque Off (STO) mode when the Connection is set to Standard in the Device Definition dialog box of the Logix Designer application (see Configure the Device Definition on page 156 for details). To be configured for Hardwired STO mode, it is also required that no Network Safety connection has been made. Hardwired STO Operation If the Safety Supervisor state is waiting (8) or waiting with torque permitted (51), then the safety control is in the out-of-box state. See Table 23 on page 99. For hardwired control of the STO: • The STO function must be in Hardwired STO mode. • The safety inputs must be wired appropriately (see details below). • In hardwired safety mode, the bi-polar safety output is not operational. It can only be used in integrated safety mode. The four 24V DC discrete safety inputs are organized into two pairs. Safety Input 0 and 1 (SI0 and SI1) along with Test Output 0 and 1 are intended to interface to dual-channel equivalent safety devices. Safety Inputs 2 and 3 (SI2 and SI3) are intended to interface to Output Solid State Devices (OSSD). Only one pair of inputs can be used at a time. See Safety I/O Operation on page 130 for additional information. If either pair of safety inputs are energized (SI0 and SI1, or SI2 and SI3), the output power transistors turn on. If either of the safety enable inputs are de-energized, then all output power transistors turn off. The hardwired STO response time is less than 12 ms. Figure 44 shows the timing diagram of the hardwired STO in normal operation. Figure 47 shows the timing diagram of the hardwired STO function while Safety Inputs are discrepant. All safety inputs in hardwired mode are configured as shown in Table 24. The 1 ms On to Off delay configuration is to reject test pulses from other devices that are connected to the drive. In hardwired mode, SI0 and SI1 are configured for pulse testing by the Armor PowerFlex drive. SI2 and SI3 are not configured for pulse testing. Torque is enabled when either safety input pair is enabled. 100 Rockwell Automation Publication 35-UM001G-EN-P - September 2024 Chapter 6 Safety Functions Table 24 - Hardwired Safety Input Pair Configuration Parameter Off to On delay On to Off delay Discrepancy time Value 100 ms 1 ms 0.9 s Figure 42 and Figure 43 show wiring examples for both hardwired input pair. Figure 42 - Hardwired STO - Dual Channel Device Wiring test pulses sent from drive I/O 1 5 4 Pin 1: Test Output 1 Pin 2: Safety Input 1 Pin 3: Input Common Pin 4: Safety Input 0 Pin 5: Test Output 0 2 3 Dual-Channel Equivalent Safety Device Figure 43 - Hardwired STO - Signal Switching Device using External Power Supply 1 Wiring test pulses sent from OSSD device + 24V DC - 4 5 Pin 1: Test Output 1 Pin 2: Safety Input 3 Pin 3: Input Common Pin 4: Safety Input 2 Pin 5: Test Output 0 2 3 OSSD1 Light Curtain or Safety Mat OSSD2 Figure 44 - Normal Operation (Safety Input) Si0 24V (Safety Input) Si1 24V 0 .9 Safety State 0 .9 8 = Waiting 51 = Wait w Trq STO Fault No Fault STO Active Disable Torque Torque Disabled Torque Disabled A Letter A B C D B 51 = Wait w Trq C D Description Set Safety Input SI0 = 0 volts Set Safety Input SI1 = 0 volts within 0.9 seconds Set Safety Input SI0 = 24 volts Set Safety Input SI1 = 24 volts within 0.9 seconds Rockwell Automation Publication 35-UM001G-EN-P - September 2024 101 Chapter 6 Safety Functions Hardwired STO Daisy Chaining Signal You can daisy-chain the hardwired STO signal on multiple Armor PowerFlex drives. Daisy Chain Using External 24V DC Source • • You must use SI2 and SI3 Using a 24V DC signal without pulse testing achieves category 3 Figure 45 - Hardwired STO Daisy Chain Wiring Example using 24V DC BK WH BU Daisy Chain Signal Test Outputs — Pulse Testing • • • • One drive (typically the first) must use SI0 and SI1 Test outputs for SI0 and SI1 provide pulse testing The rest of the drives must use SI2 and SI3 Category 4 requires pulse testing so, an OSSD must be used to achieve Category 4 Figure 46 - Hardwired STO Daisy Chain Wiring Example for Signal Test Outputs — Pulse Testing For cable and media selection information for daisy chaining the hardwired STO signal, see the On-Machine Media for Armor PowerFlex, ArmorStart, and ArmorConnect Products Selection Guide, publication 280PWR-SG001. Hardwired STO Fault Operation Both STO safety inputs must turn off together, otherwise a Hardwired Discrepancy (102) STO fault occurs, even if the first safety input gets turned on again. All hardwired inputs must be set to zero for 1 ms, for the fault to be cleared. Figure 47 and Figure 48 describe this operation. If both input pairs become energized (SI0 or SI1, and SI2 or SI3), a Both Pairs Active (105) STO Fault type occurs. All inputs must be set to zero for 1 ms for the fault to be cleared. 102 Rockwell Automation Publication 35-UM001G-EN-P - September 2024 Chapter 6 Safety Functions Figure 47 - System Operation when Safety Enable Inputs Mismatch Occurs (Safety Input) SI0 24V (Safety Input) SI1 24V 0.9 Safety State 1.0 51 51 = Wait w Trq 8 = Waiting Safety Fault Faulted STO Active Disable Torque Torque Disabled Torque Disabled A Letter A B C D E F G 0.9 B C D E F G Description Set Safety Input SI0 = 0 volts Discrepancy fault after 0.9 seconds Set Safety Input SI1 = 0 volts Discrepancy fault cleared after 1.0 seconds Set Safety Input SI0 = 24 volts Set Safety Input SI1 = 24 volts Clear Armor PowerFlex Fault Figure 48 - System Operation in the Event That the Safety Enable Inputs Mismatch Momentarily (Safety Input) Si0 24V (Safety Input) Si1 24V 0.9 Safety State 1.0 51 = Wait w Trq 8 = Waiting 51 Safety Fault Faulted STO Active Disable Torque Torque Disabled Torque Disabled A Letter A B C D E F G 0.9 B C D E F G Description Set Safety Input SI0 = 0 volts Discrepancy fault after 0.9 seconds Set Safety Input SI1 = 0 volts Discrepancy fault cleared after 1.0 seconds Set Safety Input SI0 = 24 volts Set Safety Input SI1 = 24 volts Clear Armor PowerFlex Fault ATTENTION: The STO fault is detected upon demand of the STO function. After troubleshooting, a safety function must be executed to verify correct operation. Rockwell Automation Publication 35-UM001G-EN-P - September 2024 103 Chapter 6 Safety Functions IMPORTANT Integrated Safety Features A Hardwired Input Discrepancy fault (102) and both pairs active fault (105), can be reset by placing all inputs in the off state for more than 1 second. Any other STO fault types can only be cleared in hardwired STO mode by power cycling or resetting the device. The Armor PowerFlex drive is suitable for use in a safety-control network that meets the requirements up to and including the following: • SIL CL 3 according to IEC 62061 and IEC 61508 • Category 4, PLe as defined in ISO 13849-1 The TÜV Rheinland group has approved Armor PowerFlex drives with integrated Safe Torque Off (STO) and Safe Stop 1 functions (Timed SS1 and Monitored SS1 and SBC) for use in safetyrelated applications up to ISO 13849-1 Performance Level e (PLe), SIL CL 3 per IEC 61508, IEC 61800-5-2, and IEC 62061, in which removing the motion-producing power is considered to be the safe state. See the GuardLogix Safety Application Instruction Set Reference Manual, publication 1756-RM095, for more information on the Drive Safety instructions and TÜV Rheinland certification. Integrated Safety Applications Armor PowerFlex 35S drives feature integrated safety I/O (4 safety inputs, 2 test outputs, and 1 bipolar safety output) as well as integrated Safe Stop and Safe Monitor functions. A safety input only connection can be used to monitor the safety status of the Armor PowerFlex device in another safety controller. See Configure Safety Listen Only Connection on page 200, for instructions how to configure this connection and for more information. Drive-based safe stop functions that are built in to the Armor PowerFlex 35S drives are: • Safe Torque Off • Timed Safe Stop 1 • Monitored Safe Stop 1 • Safe Brake Control, stop functions Controller-based safety functions operate in GuardLogix 5580 or Compact GuardLogix 5380 controllers and use the EtherNet/IP network to communicate with the safety I/O. Drive Safety instructions use safety feedback, provided by the Armor PowerFlex drive to the safety task of the controller, to perform safe monitor functions. The supported Drive Safety instructions are: • Safety Feedback Interface (SFX) • Safe Stop 1 Monitored (SS1) • Safely limited Speed (SLS) • Safely limited Position (SLP) • Safe Direction (SDI) • Safe Brake Control (SBC) When used for safe speed monitoring, the drive is configured for single-feedback to achieve the following safety rating: Single-feedback configurations using safety encoders provide up to SIL 2 PLd capability. IMPORTANT 104 Drive Safety instructions are only available in Logix Designer version 32.00…34.xx and 36.xx or later (not compatible with 35.xx), and can only be used with Compact GuardLogix 5380 and GuardLogix 5580 controllers. Rockwell Automation Publication 35-UM001G-EN-P - September 2024 Chapter 6 Safety Functions Integrated Safety System Application Requirements Safety application requirements include evaluating average frequency of dangerous failure rates (PFH), system reaction time settings, and functional verification tests that fulfill the SIL criteria. Create, record, and verify the safety signature as part of the required safety application development process. The safety controller creates the safety signature. The safety signature consists of an identification number, date, and time that uniquely identifies the safety portion of a project. This signature covers all safety logic, data, and safety I/O configuration. For safety system requirements, including information on the safety network number (SNN), verifying the safety signature, and functional verification tests, see the GuardLogix Controller Systems Safety Reference Manuals. See Additional Resources on page 12. IMPORTANT You must read, understand, and fulfill the requirements that are detailed in the appropriate GuardLogix controller systems safety reference manual before operating a safety system that uses a GuardLogix controller and an Armor PowerFlex drive. See Additional Resources on page 12. Drive-based Integrated Safe Stop Functions IMPORTANT Safety Output Monitor Value is not safety data and has no defined safe state. Use Output Monitor Value for diagnostic purposes only. The information in this section describes information that is common to the integrated Safe Torque Off, Timed Safe Stop 1, Monitored Safe Stop 1, and Safe Brake Control stop functions that are built into the drive. Detailed information for each function follows this topic. • Safe Torque Off page 106 • Timed Safe Stop 1 page 113 • Monitored Safe Stop 1 page 114 • Safe Brake Control page 116 Safety Output Assembly Safe Stop Function Tags The safety output controller for Integrated Safe Speed consists of different Logix tags: • Pass through status and faults • Safety stop function commands • Safety I/O commands See Safety Output Tags on page 209 for a list of Safety Output Assembly Tags. Safety Input Assembly Safe Stop Function Tags The safety input assembly for Integrated Safe Speed consists of different Logix tags: • Connection status • Safety feedback and stop function status • Safety I/O status See Safety Input Tags on page 207 for a list of Safety Input Assembly Tags. ATTENTION: Safety I/O connections and produced/consumed connections cannot be automatically configured to fault the controller if a connection is lost and the system transitions to the safe state. If you must detect a device fault so that the system maintains the required SIL level, you must monitor the Safety I/O CONNECTION_STATUS bits and initiate the fault via program logic. Rockwell Automation Publication 35-UM001G-EN-P - September 2024 105 Chapter 6 Safety Functions Safety Function in Response to Connection Event The drive allows for a safety function to be executed when the safety connection to the drive is lost or the connection enters the idle state. This operation is referred to as the connection action. There are two configurable connection actions that are defined as follows: • Connection Loss Action - The safety function to be executed if the network connection from the drive to the safety controller is lost or closed. • Connection Idle Action - The safety function to be executed if the safety controller that is connected to the drive enters program mode. In both of theses cases, the safety function must be executed by the drive. Therefore, only the drive-based safety functions are used in these cases. The following drive-based safety functions are supported as a connection loss action and connection idle action: • STO • SS1 The action can be configured in the Logix Designer application on the Actions page. See Configure Safety Actions on page 203, for more information. Integrated Safe Torque Off Function The Safe Torque Off (STO) feature provides a method, with a sufficiently low probability of failure, to force the output power to a disabled state. When the command to execute the STO function is received by the Armor PowerFlex drive, the output power device transitions to an Off state, which results in a condition where the motor is coasting. The Integrated STO response time is less than 10 ms. ATTENTION: Safe Torque Off (STO) will prevent the motor from applying torque to a system but in some systems torque is also applied to the mechanical system by a suspended load, unbalanced load, back pressure, and so on. In such a system, application of a mechanical brake is required to hold the load while motor torque is disabled by STO. You can use the STO circuit in combination with other safety devices to achieve the stop and protection-against-restart as specified in IEC 60204-1. These conditions must be met for integrated control of the STO function: • You must have a GuardLogix family of safety controllers project with an EtherNet/IP network connection configured. • You must add the drive to the Ethernet network connection in the safety controller I/O tree. IMPORTANT Integrated STO will not work unless an IP address has been configured for the drive. See Set the IP Address on page 69. The safety reaction time is the time from when the Armor PowerFlex drive STO command receives the CIP Safety™ packet that triggers a safe stop to the initiation of the configured Stop Type. See Safety Data for Safety Functions with Safety Feedback on page 95, for details. Safe Torque Off Activation Safe Torque Off can be initiated by one or more sources: • STO Output – Setting the Safety Output Assembly Tag (devicename:SO.STOOutput1 = 0) • SS1 Complete – Completion of a Safe Stop 1 • Stop Fault – Any Safety Fault • Connection Loss – Loss of connection to the safety controller 106 Rockwell Automation Publication 35-UM001G-EN-P - September 2024 Chapter 6 • Safety Functions Connection Idle – Safety controller in program mode When STO is activated, all sources of activation are stored in an attribute as a bit mask. The attribute can then be read to determine the causes of a STO activation. Figure 49 shows the operation of the STO activation attribute. The STO Activation attribute can be read with a Message (MSG) Instruction (see attribute 265 in Armor PowerFlex AC Drives CIP Objects and Attributes Reference Data, publication 35-RD001). Figure 49 - Safe Torque Off Activation STO Output SS1 Complete Safety Stop Fault Safety Limit Fault Safety Limit Active Connection Loss (1) Connection Idle (2) STO Activation STO Output SS1 Complete Safety Stop Fault Logical OR Safety Limit Fault STO Active STO to SBC Delay Torque Disabled Safety Limit Active Negative Value: Delay = |Value| Positive Value: Delay = 0 Safety Fault: Delay = 0 Connection Loss Connection Idle (1) Connection Loss Action = STO (2) Connection Idle Action = STO Safe Torque Off Reset After torque is disabled due to a STO activation, the STO function must be reset to enable torque. When the STO function must be reset, the following attribute values are set: • devicename:SI.STOActive = 1 • devicename:SI.RestartRequired = 1 The steps to reset the STO function depend on the cause of STO activation and the Restart/ Cold Start Type configured in the module. • Safety Fault STO Activation Reset IMPORTANT • • • When a Safety Fault activates the STO function, the cause of the safety fault must be removed before STO can be reset, regardless of the configured restart type. Once the cause of the fault is removed, a 0 to 1 transition on the devicename:SO.ResetRequest tag resets the STO function to the Torque Enabled state. Connection Loss/Idle STO Activation Reset If a connection loss/idle event activates the STO function, the connection must be reestablished and running before the STO function can be reset. The function must be reset based on the configured Cold Start type. Automatic Cold Start/Restart Type Operation If there are no Safety Faults and no safety demands, the STO function can be reset. Manual Cold Start/Restart Type Operation If there are no Safety Faults and no safety demands present in the module, the STO function can be reset by a 1 to 0 transition on the devicename:SO.STOOutput tag then a 0 to 1 transition on devicename:SO.ResetRequest tag. Setting devicename:SO.STOOutput = 1 and devicename:SO.RequestReset = 1 in the same program scan, enables torque. Rockwell Automation Publication 35-UM001G-EN-P - September 2024 107 Chapter 6 Safety Functions Safe Torque Off Delay A delay to provide time for the drive to stop the load in response to STO Active can be programmed. This delay time is referred to as STO Delay. If no delay is desired, set the STO Delay to zero. The STO Delay must be a positive integer value. If Safe Brake Control is being used, the STO delay must be zero. If an STO delay is desired with the use of the Safe Brake Control function, see Safe Brake Control Function on page 116 for information on how to configure STO to SBC delay. If STO is activated by a safety fault, any configured delay is ignored, and torque is disabled instantly. Safe Torque Off Operation The operation of the STO function and its attributes is dependent on the configuration of the STO function and the activation reason. For all STO activations besides safety fault, the operation of STO is dependent on STO Delay. For STO activations caused by a safety fault, the operation ignores STO Delay. See the following sections for more information. Figure 50 - STO Without Delay SO.STO Output (1) STO Activation(2) Disable Torque 0x01 =STO Output 0x00 SI.STO Active (3) Disable Torque SI.Torque Disabled (3) Torque Disabled SI.Restart Required (3) Restart Required SO. Reset Request (1) Required If Restart Type = Manual (1) Safety Output Assembly Restart Type = Automatic 108 (2) Safe Stop Function Attribute (3) Safety Input Assembly Restart Type - Manual Rockwell Automation Publication 35-UM001G-EN-P - September 2024 Chapter 6 Safety Functions Safe Torque Off With Delay Operation When the STO Delay is configured for a positive nonzero value, the delay is inserted between STO Active and Torque Disabled. The STO Delay is meant to serve as a delay between the configured STO drive stop action and when torque is disabled. The delay allows the drive to complete the stop before torque is disabled. This operation is effectively a Timed Safe Stop 1 function. See Safe Stop 1 Function on page 111 for information on how to configure a drive stop type in response to a STO activation. Figure 51 shows the timing of STO status and torque attributes in response to a STO activation, along with the restart type behavior, when STO Delay is configured. Figure 51 - STO with Delay STO Delay Velocity SO. STO Output (1) STO Activation (2) Disable Torque 0x00 0x01 = STO Output SI.STO Active(3) STO Active STO Active STO Active SI.TorqueDisabled (3) Torque Disabled SI.RestartRequired (3) Restart Required SO.ResetRequest (1) Required If Restart Type = Manual (1) Safety Output Assembly (2) Safe Stop Function Attribute Restart Type = Automatic IMPORTANT (3) Safety Input Assembly Restart Type = Manual The Safe Brake Control (SBC) Mode must be set to ‘Not Used’ to permit STO Delay. If Mode is not set to ‘Not Used’, Delay is set to zero. Rockwell Automation Publication 35-UM001G-EN-P - September 2024 109 Chapter 6 Safety Functions Safe Torque Off Safety Fault When the Armor PowerFlex drive experiences a STO Fault, the Armor PowerFlex drive is placed in the safe state and the cause of the fault is recorded. If the STO function detects a fault, it sets the following attributes: • devicename:SI.SafetyFault = 1 • devicename:SI.RestartRequired = 1 • STO Fault Type, see Safe Torque Off Fault on page 127 For more information on STO Fault Types and troubleshooting methods, see Monitor Safety Status and Faults via a Message Instruction on page 126. When a safety fault occurs in the module, the STO function is forced to the Safe State, which is the Torque Disabled state. In this case, the configured STO Delay value is bypassed and torque is immediately disabled. Figure 52 shows the timing of STO and torque attributes in response to STO activation by a Safety Fault. Clearing a Safety Fault requires correcting the fault condition, then a 0 to 1 transition on Request Reset. Figure 52 - STO with Safety Fault SI. Safety Fault (1) Safety Fault STO Activation (2) 0x04 = Safety Stop Fault SI.STO Active(3) Disable Torque SI.Torque Disabled (3) Torque Disabled SI.Restart Required (3) Restart Required SO.Reset Request (1) Always Required to Reset a Fault (1) Safety Output Assembly (2) Safe Stop Function Attribute Fault Cleared (3) Safety Input Assembly ATTENTION: If STO activation by a safety fault occurs, the configured STO Delay time is ignored, and torque is immediately disabled. 110 Rockwell Automation Publication 35-UM001G-EN-P - September 2024 Chapter 6 Safety Functions Safe Stop 1 Function The Safe Stop 1 (SS1) function signals the configured SS1 Stop Action Source to initiate a stopping action, then the safety module monitors the stop. When the Safe Stop 1 is complete, STO is activated and torque is disabled. If the drive does not complete the stop within the limits that are configured in the Safe Stop 1 function, an SS1 Fault is annunciated. Safe Stop 1 Activation Safe Stop 1 can be initiated by one or more sources: • SS1 Request – Setting the Safety Output Assembly Tag (devicename:SO.SS1Request1 = 1) • Limit Active – Reserved for future use • Connection Loss – Loss of connection to the safety controller • Connection Idle – Safety controller in program mode When SS1 is activated, all sources of activation are stored in an attribute as a bit mask and the attribute can then be read to determine the causes of an SS1 activation. Figure 53 shows the operation of the SS1 activation attribute. The SS1 Activation attribute can be read with a message instruction (see attribute 289 in Armor PowerFlex AC Drives CIP Objects and Attributes Reference Data, publication 35-RD001). Unlike the STO function, SS1 does not get activated by a safety fault. Figure 53 - Safe Stop 1 Activation SS1 Activation SS1 Request SS1 Request Safety Limit Active Safety Limit Active Connection Loss (1) Connection Loss Connection Idle (2) Logical OR SS1 Active Connection Idle (1) Connection Loss Action = SS1 (2) Connection Idle Action = SS1 Safe Stop 1 Reset After an SS1 action is complete, the SS1 function must be reset to enable torque. When the SS1 Function needs to be reset, the following attribute values are set: • devicename:SI.SS1Active = 1 • devicename:SI.RestartRequired = 1 The steps to reset the SS1 function depend on the cause of SS1 activation and the Restart/Cold Start Type configured in the module. • Connection Loss/Idle SS1 Activation Reset If a connection loss/idle event activates the SS1 function, the connection must be reestablished and running before the SS1 function can be reset. The function must be reset based on the configured Cold Start type. • Automatic Cold Start/Restart Type Operation If there are no Safety Faults present in the module, the SS1 function can be reset by a 1 to 0 transition on the devicename:SO.SS1Request1 tag. • Manual Cold Start/Restart Type Operation If there are no Safety Faults in the module, the SS1 function can be reset by a 1 to 0 transition on the devicename:SO.SS1Request1 tag then a 0 to 1 transition on devicename:SO.ResetRequest tag. Rockwell Automation Publication 35-UM001G-EN-P - September 2024 111 Chapter 6 Safety Functions SS1 Safety Fault When an SS1 Safety Fault occurs, the STO function is activated immediately and torque is disabled. Figure 54 describes the operation of SS1 when an SS1 fault is detected. The ‘Safe State’ of the SS1 function is the Torque Disabled state. If the SS1 function detects a fault, it sets: • devicename:SI.SafetyFault = 1 • devicename:SI.RestartRequired = 1 • SS1 Fault Type, see Safe Stop 1 Fault on page 128 Clearing a Safety Fault requires correcting the fault condition and a 0 to 1 transition on Request Reset. For more information on SS1 Safety Faults, see Monitor Safety Status and Faults via a Message Instruction on page 126. Figure 54 - Safe Stop 1 Fault Operation Velocity SS1 Max Stop Time SS1 Max Stop Time Fault Occurs (Feedback Velocity > Expected Velocity) Coast-to -stop Standstill Speed SO.SS1Request(1) SS1 Activation(2) SS1 Request 0x00 0x01 = SS1 Request SI.SS1Active(3) SS1 Active S1.SafetyFault(1) Safety Fault 1 = No Fault SS1 Fault Type (2) STO Activation(2) 3 = Deceleration Rate 0x04 = Safety Stop Fault 0x00 SI.STOActive(3) Disable Torque SI.TorqueDisabled(3) Torque Disabled SI.RestartRequired(3) Restart Required SO.RequestReset(1) Always Required to Reset a Fault (1) Safety Output Assembly (2) Safe Stop Function Attribute 112 0x00 (3) Safety Input Assembly Rockwell Automation Publication 35-UM001G-EN-P - September 2024 0x00 Chapter 6 Safety Functions Timed Safe Stop 1 A Timed Safe Stop 1 involves initiating motor deceleration and initiating the STO function after the configured time delay. Timed Safe Stop 1 Operation When the Armor PowerFlex drive is configured for Timed Safe Stop 1 Mode, the Safe Stop 1 function is initiated by setting the devicename:SO.SS1Request1 safety output tag. This sets the ‘SS1 Request’ bit in the SS1 Activation attribute and sets the devicename:SI.SS1Active safety input tag. The SS1 function waits for the configured SS1 Max Stop Time, then sets the SS1 Complete flag in the STO Activation attribute, which sets STO Active to Disable Torque. In Timed Safe Stop 1 mode, speed and deceleration are not monitored so this mode does not require Safety Feedback. Figure 55 shows the timing of SS1 status and torque attributes in response to an SS1 activation, along with the restart type behavior. Figure 55 - Timed Safe Stop 1 SS1 Ext Max Stop Time Velocity SO.SS1Request(1) SS1 Activation(2) 0x00 SI.SS1Active(3) STO Activation(2) 0x00 0x01 = SS1 Request Active 0x00 0x02 = SS1 Complete SI.STOActive(3) Disable Torque SI.TorqueDisabled(3) Torque Disabled SI.RestartRequired(3) 0x00 Restart Required Required if Restart Type = Manual SO.RequestReset(1) (1) Safety Output Assembly (2) Safe Stop Function Attribute Restart Type = Automatic (3) Safety Input Assembly Restart Type = Manual Rockwell Automation Publication 35-UM001G-EN-P - September 2024 113 Chapter 6 Safety Functions Monitored Safe Stop 1 A Monitored Safe Stop 1 involves monitoring the motor feedback deceleration rate and time, then initiating an STO activation when the motor feedback speed is below a specified limit. Monitored Safe Stop 1 Operation When the Armor PowerFlex drive is configured for Monitored Safe Stop 1 Mode, the Safe Stop 1 function is initiated by setting the devicename:SO.SS1Request1 safety output tag. This sets the ‘SS1 Request’ bit in the SS1 Activation attribute, and also sets the devicename:SI.SS1Active safety input tag. After the SS1 Active bit is set, the configured SS1 Decel Monitor Delay timer begins. After the configured Decel Monitor Delay expires, an internal speed ramp value is computed every time that the encoder is sampled. If the magnitude of devicename:SI.FeedbackVelocity exceeds the sum of the internal ramp plus Decel Speed Tolerance, the SS1 Fault Type attribute is set to ‘Deceleration Rate’ and the SS1 Fault attribute is set to Faulted. Figure 56 describes the equations that are used for computing the deceleration (decel) reference rate and tolerance. Figure 56 - SS1 Deceleration Reference Rate and Tolerance Calculation Decel Reference Speed Decel Reference Rate = ---------------------------------------------1000 × Stop Delay If Time Units = Seconds, Decel Reference Rate × Position Scaling SS1 Decel Ref Rate = – ---------------------------------------------------------------------------------------------Feedback Resolution Decel Reference Tolerance × Position Scaling SS1 Decel Tolerance = ----------------------------------------------------------------------------------------------------------Feedback Resolution If Time Units = Minutes, Decel Reference Rate × Position Scaling SS1 Decel Ref Rate = – -----------------------------------------------------------------------------------------Feedback Resolution × 60 l A Configured Decel Reference Rate of 0 disables the ramp check. SS1 faults if the drive does not slow to less than the Standstill Speed. If the magnitude of devicename:SI.FeedbackVelocity is not less than the configured Standstill Speed before Max Stop Time expires, the SS1 Fault Type is set to ‘Maximum Time’ and the SS1 Fault attribute is set to ‘Faulted’. Figure 57 describes the equations that are used for computing the standstill speed. Figure 57 - SS1 Standstill Speed Calculation If Time Units = Seconds, Standstill Speed × Position ScalingSS1 Standstill Speed = ---------------------------------------------------------------------------------Feedback Resolution If Time Units = Minutes, Standstill Speed × Position ScalingSS1 Standstill Speed = -----------------------------------------------------------------------------Feedback Resolution × 60 Where Standstill Speed, Position Scaling, and Feedback Resolution are user-configured values. 114 Rockwell Automation Publication 35-UM001G-EN-P - September 2024 Chapter 6 Safety Functions When the magnitude of devicename:SI.FeedbackVelocity is less than the Standstill Speed, the SS1 Complete flag in the STO Activation attribute is set, and STO Active is set. If STO Delay is positive (and SBC Mode = Not Used) or if STO to SBC Delay is negative (and STO Activates SBC = Linked), then the Torque Disabled attribute is set after the configured time delay. Otherwise, the Torque Disabled attribute is set immediately. Figure 58 shows the timing of the Monitored SS1 operation, along with the restart type behavior. Figure 58 - Monitored Safe Stop 1 SS1 Max Stop Time Velocity SS1 Decel Ref Rate SS1 Decel Monitor Delay Standstill Speed SO.SS1Request(1) SS1 Activation(2) SS1 Request 0x00 SI.SS1Active(3) STO Activation(2) 0x00 0x01 = SS1 Request SS1 Active 0x00 0x02 = SS1 Complete SI.STOActive(3) Disable Torque SI.TorqueDisabled(3) Torque Disabled SI.RestartRequired(3) Restart Required SI.RequestReset(1) Required if Restart Type = Manual (1) Safety Output Assembly (2) Safe Stop Function Attribute Restart Type = Automatic 0x00 (3) Safety Input Assembly Restart Type = Manual Speed units are configured by the ‘Position Units’ and ‘Time Units’ Add-on Profile Controls on the Scaling page. A Configured Decel Reference Rate of 0 disables the ramp check. SS1 will fault if the drive does not slow to less than the Standstill Speed within Max Stop Time. Rockwell Automation Publication 35-UM001G-EN-P - September 2024 115 Chapter 6 Safety Functions Safe Brake Control Function The Safe Brake Control (SBC) function uses the module’s safety outputs to control an electromechanical brake that is attached to the motor. The SBC function releases the brake to allow motion or engages the brake to prevent motion. Safe Brake Control Activation Safe Brake Control can be initiated by one or more sources: • SBC Output – Clearing the Safety Output Assembly Tag (devicename:SO.SBCOutput1 = 0) • STO Active – SBC is configured as ‘Linked’ • Safe Stop Fault – Any Safety Fault • Safe Limit Fault – Reserved for future use When SBC is activated, all sources of activation are stored in an attribute as a bit mask, and the attribute can then be read to determine the causes of an SBC activation. Figure 59 shows the operation of the SBC activation attribute. The SBC Activation attribute can be read with a message instruction (see attribute 365 in Armor PowerFlex AC Drives CIP Objects and Attributes Reference Data, publication 35-RD001). Figure 59 - Safe Brake Control Activation SBC Activation SBC Output STO Active(1) Safety Stop Fault Safety Limit Fault SBC Output STO Active Logical OR Safety Stop Fault SBC Active Safety Limit Fault STO to SBC Delay Brake Engaged Positive Value: Delay = |Value| Negative Value: Delay = 0 Safety Fault: Delay = 0 (1) STO Activates SBC = Linked If the SBC Activation bit mask indicates that only STO Active is the source of activation, then the STO to SBC Delay is executed. If the activation is not by STO Active, or other activation bits are also set, the STO to SBC Delay is not executed and the brake is immediately engaged. Safe Brake Control Reset After the brake is engaged due to an SBC activation, the SBC function must be reset to release the brake. When the SBC function must be reset, the following attribute values are set: • devicename:SI.SBCActive = 1 • devicename:SI.RestartRequired = 1 The steps to reset the SBC function depend on the cause of SBC activation and the Restart/ Cold Start Type configured in the module. IMPORTANT • • • 116 When the SBC function is activated by a Safety Fault, the cause of the safety fault must be removed before the SBC function can be reset, regardless of the configured restart type. Safety Fault SBC Activation Reset Once the fault is removed, a 0 to 1 transition on devicename:SO.ResetRequest tag resets the SBC function to the Brake Released state. Automatic Cold Start/Restart Type Operation If there are no Safety Faults in the module, the STO function can be reset by a 0 to 1 transition on the devicename:SO.SBCOutput tag. Manual Cold Start/Restart Type Operation Rockwell Automation Publication 35-UM001G-EN-P - September 2024 Chapter 6 Safety Functions If Restart Type is set to ‘Manual’ and there are no Safety Faults in the module, the SBC function can be reset by a 0 to 1 transition on the devicename:SO.SBCOutput tag, then a 0 to 1 transition on devicename:SO.ResetRequest tag. Setting devicename:SO.SBCOutput = 1 and devicename:SO.RequestReset = 1 in the same scan enables torque. Safe Brake Control Modes SBC Mode specifies if the SBC functionality is used and how the safety outputs controlling the brake operate. The mode also changes the instances of the CIP objects controlling the safety outputs. The module supports the following modes. Not Used In ‘Not Used’ mode, the SBC function is not used by the application. The associated safety outputs are not under SBC control, and can be configured independently. The safety outputs are mapped to the following CIP objects: • So0: Safety Discrete Output Point Object Instance 1 • So1: Safety Discrete Output Point Object Instance 2 • Safety Dual Channel Output Object Instance 1 IMPORTANT If the Safe Brake Mode is set to ‘Not Used’, then the state of the two safety outputs So0 and So1 is controlled by the Safety Output Assembly tags; otherwise, the two Safety Outputs are controlled by the Safe Brake Function. IMPORTANT If the Safe Brake Mode is set to ‘Not Used’, then setting the Safety Output tag devicename:SO.SBCOutput1 = 1 sets the SBC Fault and sets the SBC Fault Type to ‘Config’. Used, No Test Pulses In ‘Used, No Test Pulses’ mode, the associated safety outputs are not pulse tested. The associated safety outputs are under SBC control and cannot be configured independently. The safety outputs are mapped to the following CIP objects: • So0: Safety Discrete Output Point Object Instance 3 • So1: Safety Discrete Output Point Object Instance 4 • Safety Dual Channel Output Object Instance 2 Used, Test Pulses In the ‘Used, Test Pulses’ mode, the safety outputs are under SBC control and cannot be configured independently. The safety outputs are mapped to the same CIP objects as the ‘Used, No Test Pulses’ mode. There is no difference in implementation of Safety Outputs pulse testing in SBC control versus direct control. See Safety I/O Operation on page 130 for pulse test behavior.SBC Operation when Activated by Safety Output Assembly. IMPORTANT When pulse testing is used to achieve the maximum safety rating (SIL 3 Category 4, PLe), the safety output wiring must be protected against external damage by cable ducting, conduit, armored cable, or other means. See ISO 13849-2:Table D.4, for additional information. Rockwell Automation Publication 35-UM001G-EN-P - September 2024 117 Chapter 6 Safety Functions IMPORTANT If the Safe Brake Mode is set to ‘Used’, then the Safety Input Assembly tags associated with safety outputs will be forced to: devicename:SI.Out00Monitor = 0 devicename:SI.Out01Monitor = 0 devicename:SI.Out00Status = 0 devicename:SI.Out01Status = 0 devicename:SI.Out00Ready = 0 devicename:SI.Out01Ready = 0 When the SBC function is activated by clearing the devicename:SO.SBCOutput tag, the associated safety outputs are de-energized, which forces the brake to engage, and torque is still enabled. Figure 60 shows the timing of SBC attributes when the SBC function is executed independently. Figure 60 - SBC Operation by Safety Output Assembly SO.SBCOutput (1) Engage Brake SI.TorqueDisabled (3) Torque Enabled SBC Activation(2) 0x00 0x01 = SBC Output SI.SBCActive(3) Engage Brake SI.BrakeEngaged(3) Brake Engaged So0 and So1(4) Brake Engaged SO.ResetRequest (1) Restart Required Required If Restart Type = Manual (1) Safety Output Assembly (2) Safe Stop Function Attribute Restart Type = Automatic 118 (3) Safety Input Assembly (4) 24V DC Safety Output Restart Type = Manual Rockwell Automation Publication 35-UM001G-EN-P - September 2024 Chapter 6 Safety Functions STO Activates SBC Operation If the SBC function is configured to link STO and SBC activation, any STO activation will cause the SBC function to be activated as well. The brake is engaged (de-energized) by the SBC function when torque is disabled by the STO function. If the SBC function is configured to link STO activation to SBC activation, you can configure an STO to SBC Delay time where: • STO to SBC Delay > 0 configures a delay between when STO is activated and the brake is engaged. Figure 61 describes this operation. • STO to SBC Delay < 0 configures the brake to engage when STO is activated and delays disabling torque. Figure 62 describes this operation. Figure 61 - SBC Linked to STO with Positive Delay SI. STO Active(1) Disable Torque SI.TorqueDisabled(1) Torque Disabled SBC Activation(2) 0x00 0x02 = STO Active SI.SBCActive(1) Engage Brake (STO to SBC Delay) > 0 SI.BrakeEngaged (1) Brake Engaged So0 and So1(3) Brake Engaged Required If Restart Type = Manual SO.RequestReset (4) (1) Safety Output Assembly (2) Safe Stop Function Attribute (3) 24V DC Safety Output (4) Safety Output Assembly Restart Type = Manual Restart Type = Automatic Figure 62 - SBC Linked to STO with Negative Delay SI. STO Active(1) Disable Torque SI.TorqueDisabled(1) Torque Disabled SBC Activation(2) 0x00 0x02 = STO Active SI.SBCActive(1) Engage Brake (STO to SBC Delay) <0 SI.BrakeEngaged (1) Brake Engaged So0 and So1(3) Brake Engaged Required If Restart Type = Manual SO.RequestReset (4) (1) Safety Output Assembly (2) Safe Stop Function Attribute Restart Type = Automatic (3) 24V DC Safety Output (4) Safety Output Assembly Restart Type = Manual Rockwell Automation Publication 35-UM001G-EN-P - September 2024 119 Chapter 6 Safety Functions SBC Safety Fault When the module experiences an SBC Fault, the device is placed in the safe state and the cause of the fault is recorded. If SBC function detects a fault, it sets: • devicename:SI.SafetyFault = 1 • devicename:SI.RestartRequired = 1 • devicename:SI.SBCReady = 0 For more information on SBC fault types and troubleshooting methods, see Monitor Safety Status and Faults via a Message Instruction on page 126. Connecting a Safety Brake IMPORTANT If you want a specific system safety rating, you need a safety brake that is rated at least to your desired system safety rating. In a safety chain, the lowest safety-rated component limits the overall system safety rating. The safety brake control function uses the bipolar safety outputs So0 and So1 to control a safety brake. The design of a safety brake circuit is application-dependent and is based on the following factors: • Choice of safety brake for the application • If the brake provides feedback in the application • If the application uses single or dual channel The safety brake function interfaces to the safety brake through the safety outputs So0 and So1. Figure 63 shows a wiring example for connecting a brake to the module. Usually the voltage and current rating of the safety brake is much higher than the safety outputs can directly control. To support brakes with that require higher voltage and higher current, an interposing safety relay such as the 700S-CF Safety Control Relay is required. Safety brakes typically require a voltage suppression device. Most safety brakes provide a suppression device as an option or they specify a diode or MOV to use. Use the recommended suppression devices. The drive-based SBC function does not implement checking of brake feedback; however, the available safety inputs can be used to send the status of brake feedback to the safety controller that is programmed with a diagnostic check. 120 Rockwell Automation Publication 35-UM001G-EN-P - September 2024 Chapter 6 Safety Functions Figure 63 - Safety Brake Wiring Example Pin 1: not connected Pin 2: Safety Output 1 (sinking) Pin 3: Output Power Common Pin 4: Safety Output 0 (sourcing) Pin 5: Output Power Common Safety Relay K1 M N.O. N.O. + BR 1 Brake Power Supply Safety Feedback IMPORTANT For fault-free operation of the encoder, the cable shield of the connecting cable must be grounded on both sides (encoder and control) using large area connections. On the encoder side, this is typically done in the plug connector or via the connecting cable. IMPORTANT Achievable safety rating depends on each system component. If you want SIL 2 PLd safe feedback, you need an encoder that is rated at SIL 2 PLd or greater. In a safety chain, the lowest safety rated component limits the overall system safety rating. The Armor PowerFlex product supports encoder feedback for safe speed monitor functions. Table 25 describes the supported encoder types and achievable safety ratings. Table 25 - Supported Encoder Types with Safety Ratings Encoder Type Sine/Cosine Digital AqB Achievable System Safety Rating • SIL 2 PLd with safety-rated encoder or • PLd with standard encoder(1) SIL 2 PLd with safety-rated encoder (1) When using a standard sine/cosine encoder, safety relevant data (MTTF) and safety diagnostic measures to achieve the required diagnostic coverage, must be considered. Encoder diagnostics for sine/cosine encoders that are provided by the Armor PowerFlex drive, include: encoder voltage monitoring, sin2 + cos2 vector length monitoring, zero crossing detection, and signal offset. Additional (customer supplied) diagnostics may be required. You must determine the suitability of the encoder and the system safety rating. You can achieve a PLd rating if using a standard, (not certified) sine/cosine encoder and you can get the relevant failure rate data from the manufacturer and do the calculations to show that this is acceptable for your application. Rockwell Automation offers the Bulletin 843ES CIP Safety encoders, which provide safety feedback directly to a safety programmable controller via the EtherNet/IP network. Rockwell Automation Publication 35-UM001G-EN-P - September 2024 121 Chapter 6 Safety Functions Safety Encoder Diagnostics The following encoder diagnostics are available for all supported encoder types: • Encoder Voltage Monitoring (Configurable) • Maximum Speed Limit (Configurable) • Maximum Acceleration (Configurable) • Maximum Encoder Input Frequency See Chapter 7, for information on how to configure the diagnostics. IMPORTANT These diagnostics are based on the capability of the chosen encoder and its rated limits. They do not provide a safety-rated safety function. Encoder Voltage Monitoring The voltage monitoring diagnostic samples the voltage being supplied to the encoder to confirm that its level is within its configured range. If the voltage monitoring diagnostic detects a voltage that is out of the configured range, the safety feedback instance reports a voltage monitoring fault and causes the module to enter the safe state. The following voltage monitoring ranges are supported: • 4.75…5.25V • 11.4…12.6V If a voltage range is not specified, then the voltage monitoring diagnostic is not performed. Maximum Speed Limit The maximum speed limit diagnostic detects when encoder speed is above a configured limit. If the speed of the encoder is greater than the configured max speed limit, an exceeded max speed fault is reported by the safety feedback instance. This causes the module to enter the safe state. If the encoder being used specifies a maximum speed, set the maximum speed limit configuration value to this value or lower. If the limit is configured as 0, this diagnostic is not performed. Maximum Acceleration The maximum acceleration diagnostic detects when encoder acceleration is above a configured limit. If the module detects that the acceleration of the encoder has exceeded the configured limit, a max acceleration fault is reported by the safety feedback instance. This causes the module to enter the safe state. If the encoder being used specifies a maximum acceleration, set the maximum acceleration configuration value to this value or lower. If the maximum acceleration is configured as 0, this diagnostic is not performed. Maximum Encoder Input Frequency The maximum encoder input frequency diagnostic confirms that the safety feedback signals do not exceed the maximum frequency (encoder counts per second) supported by the module. This value is not configurable and has fixed values based on the encoder type. Table 26 shows the maximum frequency based on encoder type. Table 26 - Encoder Maximum Frequency Encoder Type Digital AqB Sine/Cosine and Hiperface 122 Maximum Frequency 250 kHz 163.8 kHz Rockwell Automation Publication 35-UM001G-EN-P - September 2024 Chapter 6 Safety Functions If the module detects an encoder input frequency above the limit, a max frequency fault is reported in the safety feedback instance and the module enters the safe state. Digital AqB Diagnostics The following non-configurable diagnostic functions are implemented in the module to perform diagnostics for digital AqB encoders: • Inverse Signal Monitoring • Quadrature Error Detection Inverse Signal Monitoring The inverse signal monitoring diagnostic confirms that the inverted and noninverted signals are always at opposite signal levels. If the module detects that the Digital AqB Encoder signals are not inverse, a feedback signal lost fault is reported in the safety feedback instance and the module enters the safe state. This diagnostic is meant to detect encoder wiring errors, such as open, short, or short to power. Quadrature Error Detection The quadrature error detection confirms that the A and B signals from the digital AqB encoder do not change simultaneously. This diagnostic is also referred to as an exclusive bit check. If the module detects a quadrature error, the safety feedback instance reports a quadrature error fault and enters the safe state. A simultaneous change indicates an error with the encoder wiring or an issue with the encoder itself. Sine/Cosine and Hiperface Diagnostics The following non-configurable diagnostic functions are implemented in the module to perform diagnostics on Hiperface and or Sine/Cosine type encoders: • • • Sin2 + Cos2 Vector Length Monitoring Zero-crossing Detection Signal Offset (Sine/Cosine Encoder Type Only) IMPORTANT The digital feedback is not compatible with Armor PowerFlex drives and should not be used. Only the analog signals should be used. Sin2 + Cos2 Vector Length Monitoring The Sin2 + Cos2 vector length monitoring diagnostic confirms that the sine and cosine signals are sinusoidal and 90° apart. This diagnostic is meant to detect errors in the wiring of the encoder and problems within the encoder itself. Table 27 describes the tolerance of encoder output signal amplitudes for this diagnostic. Table 28 describes the phase tolerance of the diagnostic. If the module detects that the amplitude and or phase of the signals is out of range, the safety feedback instance reports a Sin2 + Cos2 fault and the module is placed in the safe state. Table 27 - Sin2 + Cos2 Vector Length Monitoring Amplitude Range Maximum 1.3V p-p Minimum 0.7V p-p Table 28 - Sin2 + Cos2 Vector Length Monitoring Phase Tolerance Tolerance 90° ± 20° Rockwell Automation Publication 35-UM001G-EN-P - September 2024 123 Chapter 6 Safety Functions Zero-crossing Detection The zero-crossing detection diagnostic confirms that the sine and cosine signals have a similar offset to ground. The offset tripping point is ± 50 mV. If the offset of the sine and cosine signals is greater than the tripping point, the zero-crossing detection diagnostic fails, a signal lost fault is reported in the safety feedback instance, and the module is placed in the safe state. Signal Offset The signal offset diagnostic confirms that a Sine/Cosine type encoder is producing the proper offset on the Sine and Cosine signals. This diagnostic is not performed when the feedback device type is configured as Hiperface. Table 29 describes the offset tolerance of the diagnostic. If the offset of the Sine and or Cosine signals are outside the tolerance range, the safety feedback instance reports a signal offset fault and the module is placed in the safe state. Table 29 - Signal Offset Tolerance Maximum 3.0V Controller-based Safe Monitor Functions Minimum 2.0V The Drive Safety instructions (see Table 30 on page 124) are available in the Studio 5000 Logix Designer application, version 32.00…34.xx and 36.xx or later (not compatible with 35.xx), in the Drive Safety instruction element group that is enabled when the Safety Program - MainRoutine is open (see Figure 64 on page 124 ). Table 30 - Safety Instructions Safety Instruction Description The SFX function scales feedback position into position units and feedback velocity Safety Feedback SFX into position units per time unit. SFX is used with other Drive Safety Interface instructions.SFX also provides unwind for rotary applications and position homing. The SS1 function monitors the motor deceleration rate within set limits during motor Safe Stop 1 SS1 stopping and provides an indication to initiate Safe Torque Off (STO) function when the motor speed is below the specified limit. Safely-limited Speed SLS The SLS function prevents the motor from exceeding the specified speed limit. SLP function prevents the motor shaft from exceeding the specified position Safely-limited Position SLP The limits. Safe Direction SDI The SDI function prevents the motor shaft from moving in the unintended direction. Safe Brake Control SBC The SBC function provides safe output signals to control an external brake. Figure 64 - Drive Safety Instructions Drive Safety Instructions Drive Safety Tab 124 Rockwell Automation Publication 35-UM001G-EN-P - September 2024 Chapter 6 Safety Functions Before Adding the Safety Instructions Before adding Drive Safety instructions to your Logix Designer application, you must: • Add the Armor PowerFlex drive to your safety controller project. • Configure a safety instance of Single Feedback Monitoring. Drive Safety Instruction Example Drive Safety instructions provide the following information. In this example, the Safely-limited Speed (SLS) instruction is shown. Figure 65 - SLS Drive Safety Instruction Outputs Configurable Inputs Inputs Pass Through Outputs Table 31 - Drive Safety Instruction Definitions Instruction Information Configurable Inputs Inputs Pass Through Outputs Description Safety function parameters that are used to define how the safety function operates. • Feedback SFX is the link to the SFX instruction for a safety drive. • Request initiates the safe monitoring function. • Reset initiates a safety instruction reset. Safety Output Assembly Object tags pass safety function status information from the Safety Task of the safety controller to the safety instance of the drive module. In standard I/O mode, datalinks must also be configured to provide status information to the standard controller. • Fault Type is the instruction fault code that indicates the type of fault that occurred. • Diagnostic Code provides additional details on the fault. • O1 - Output 1 indicates the status of the instruction. When ON (1), it indicates that the input conditions are satisfied. • RR - Reset Required indicates when a reset is needed to restart the instruction or to clear faults. • FP - Fault Present indicates whether a fault is present in the instruction. Rockwell Automation Publication 35-UM001G-EN-P - September 2024 125 Chapter 6 Safety Functions Safety Feedback Interface Instruction Operation Although the Safety Feedback Interface (SFX) instruction is a safety instruction, it alone does not perform a safety function. The Safety Feedback Interface (SFX) instruction scales feedback position into position units and feedback velocity into speed units per unit of time. Feedback position and velocity are read from the safety input assembly and become inputs to the instruction. The SFX instruction also sets a reference position from a home input and performs position unwind in rotary applications. Typically, one SFX instruction is used per safety drive. This instruction provides the position and velocity feedback that is used by other safety instructions, also used by the same safety drive. The drive provides safe position and velocity feedback. The outputs of the SFX instruction are used as inputs to other Drive safety instructions. For any drive to execute a controller-based safety function, an SFX instruction is required. In Figure 66, the SS1 instruction uses the Actual Speed output from the SFX instruction during execution of the SS1 safety function. Figure 66 - SS1 Instruction Armor PowerFlex Drive Feedback Position (counts) Actual Position (position units) Feedback Velocity (feedback units/second) Actual Speed (position units/second or position units/minute) Monitor Safety Status and Faults via a Message Instruction To obtain more detailed information about any faults that are detected in the drive, most faults have a corresponding fault-type attribute. Use an MSG instruction in the ladder program to read the specific attribute information. Details of the various fault-type attributes are described in the following sections. See Example: Read SS1 Fault Type on page 253 on for an example of using the MSG instruction to read status. Safety Supervisor State The Safety Supervisor State provides information on the state of the safety connection and the mode of operation. It can be read in the user's Logix program using an MSG instruction. Table 32 - Safety Supervisor State: MSG Parameter Service Code Class Instance Attribute Data Type 126 Value 0x0E 0x39 1 0x0B 11 (decimal) SINT Description Get Attribute Single Safety Supervisor – Device Status Unsigned Short Integer Rockwell Automation Publication 35-UM001G-EN-P - September 2024 Chapter 6 Safety Functions Table 33 - Device Status Value Description 1 Device is performing test diagnostics 2 No active connections 3 A fault has occurred while executing test diagnostics 4 Normal running state 5 A major recoverable fault has occurred 6 A critical fault has occurred 7 Transition state (configuring) 8 Out-of-box state: waiting 51 Out-of-box state: waiting with torque permitted 52 STO bypass state: executing with torque permitted Safety Core Fault The Safety instance has detected a nonrecoverable fault or internal error. When this detection happens, the Safety instance reboots itself and attempts to re-establish normal operation. If this fault persists through power cycles, return the drive for repair. If malfunction or damage occurs, no attempts at repair should be made. Safe Torque Off Fault The Safe Torque Off (STO) function detected a fault. The safe stop function records the specific fault type in the STO Fault Type attribute. Table 34 describes the parameters for an MSG instruction. Table 35 describes the fault types. Table 34 - Safe Torque Off Fault Type: MSG Parameter Service Code Class Instance Attribute Data Type Value 0x0E 0x5A 1 0x108 SINT Description Get attribute single Safety stop functions Drive-module safety instance STO fault type Short integer Table 35 - STO Fault Types STO Fault Type Value STO Fault Type Name 1 No Fault 3 4 5 102 104 105 Description No fault is present Internal STO diagnostics has found an issue with STO Circuit Error circuitry. Stuck Low Internal STO health Internal STO diagnostics indicate an STO signal is stuck and/or power input stuck low low Stuck High Internal STO Internal STO diagnostics indicate an STO signal is stuck health and/or power input high stuck high Hardwired Input Discrepancy Hardwired input pair are not matching. Hardwired Input Active in A hardwired input is being used while in integrated mode Integrated Mode (Both Safety Input pairs are active, only one can be active Both Pairs Active for hardwired STO control) Rockwell Automation Publication 35-UM001G-EN-P - September 2024 127 Chapter 6 Safety Functions Safe Stop 1 Fault The Safe Stop 1 (SS1) function detected a fault. The safe stop function records the specific fault type in the Safe Stop Fault attribute. Table 36 describes the parameters for an MSG instruction. The drive immediately disables torque, ignoring STO delay, if an SS1 fault is detected. If the SS1 Fault Type is reported as 1 (no fault), the SS1 fault was generated by the connected safety controller and reported to the drive over the safety connection. Table 37 describes the SS1 fault types. Table 36 - Safe Stop 1 Fault Type: MSG Parameter Service Code Class Instance Attribute Data Type Value 0x0E 0x5A 1 0x11c 284 (decimal) SINT Description Get attribute single Safety stop functions Drive-module safety instance SS1 fault type Short integer Table 37 - SS1 Fault Types SS1 Fault Type Value SS1 Fault Type Name 1 No Fault 2 Invalid Configuration 3 Deceleration Rate 4 Maximum Time Description No Fault is present The drive-based SS1 function has been requested when it has been configured as ‘not used’. Applies only when SS1 is configured for Monitored SS1 mode. The SS1 function has detected that the feedback speed is not decelerating as fast as expected. Applies only when SS1 is configured for Monitored SS1 mode. The SS1 function has detected that the device has not reached standstill speed within the maximum stopping time. Safe Brake Control Fault The Safe Brake Control (SBC) function detected a fault. The safe stop function records the specific fault type in the SBC Fault Type attribute. The SBC fault type is also recorded in [SBC Fault Type], attribute 364. Table 38 describes the parameters for an MSG instruction. Table 39 describes the fault types. Table 38 - SBC Fault Type: MSG Parameter Service Code Class Instance Attribute Data Type Value 0x0E 0x5A 1 0x16C 364 (decimal) SINT Description Get attribute single Safety stop functions Drive-module safety instance SBC fault type Short integer Table 39 - SBC Fault Types STO Fault Type Value STO Fault Type Name 1 No Fault 2 128 Invalid Configuration Description No Fault is present. The drive-based SBC function has been requested when it has been configured as ‘not used’. Rockwell Automation Publication 35-UM001G-EN-P - September 2024 Chapter 6 Safety Functions SLS, SLP, and SDI Faults The drive does not support drive-based SS2, SOS, SLS, SLP, and SDI safe stop/safety limit functions. The safety controller supports the SLS, SLP, and SDI safety function instructions. If the drive reports one of these faults, either the safety controller detected the fault and reported to the drive over the safety output connection, or the request tag was set through the safety output assembly. Additional information for these faults must be obtained from the safety controller that is associated with the drive. In addition, the safety controller is responsible for issuing a torque disable request. Safety Feedback Faults When configured for safety feedback, the drive performs periodic diagnostics to make sure that the feedback device is operating correctly. Use an explicit message to read the fault type information from the drive. For example, if an error is detected, the Safe Feedback object (class code 0x58) updates the Feedback Fault Reason attribute (attribute ID 0x09) with the reason for the fault. Table 40 - Safety Feedback Faults Safety Feedback Safety Feedback Fault Reason Value Fault Reason Name 1 No Fault 2 Invalid Configuration 3 Exceeded Max Speed Exceeded Max 4 Acceleration 5 Sin²+Cos² Error 6 9 11 107 109 Description No Fault is present. The encoder's configuration is invalid. The encoder speed has exceeded the configured maximum speed. The encoder acceleration has exceeded the configured maximum acceleration. The encoder has failed the vector length or aspect ratio checks. The encoder has exceeded the maximum number of quadrature Quadrature Error signal errors. associated dual channel feedback instance has detected a fault Supply Voltage Error The in the other encoder Feedback Signal Loss A feedback signal is missing, shorted, or open. Max input frequency Max Frequency of the configured encoder has been exceeded. Position has exceeded the maximum value supported by this Position Rollover product. Please reset the device Rockwell Automation Publication 35-UM001G-EN-P - September 2024 129 Chapter 6 Safety Functions Safety Fault Reset If the drive detects a fault, the input assembly tag device:SI.SafetyFault is set to one. A Safety Fault can result from the SS1 stopping function, STO function, safety feedback, SBC function, or other safety diagnostics. To acknowledge or clear this fault, remove the source of the safety fault and send a fault reset to the safety logic. See Figure 67 on page 130 for more information about the Integrated Safety Functions option module, state restart functionality. Figure 67 - Reset Safe Stop Fault Diagram SO.STOOutput Disable Torque Permit Torque SO.ResetRequest Reset Request SI.TorqueDisabled Torque Disabled SI.SafetyFault No Fault Faulted Reset Required SI.RestartRequired Safety Status --->Safety Fault Faulted Safety Status --->Safety Request Reset Request Restart Required Reset Required STO Active Disable Torque Torque Disabled STO Torque Disabled STO Fault No Fault Faulted A A. Set SO.STOOutput1 = 1 B. Fault Detected Safety I/O Operation B C. Set SO.STOOutput1 = 0 D. Set SO.Reset = 1 C D E E. Set SO.STOOutput1 = 1 F. Clear Fault (I/O Mode) 24V DC safety inputs and outputs: • 4 safety inputs; 2 test outputs; 1 bipolar safety output • Single channel safety inputs up to SIL 2, Category 2, PLd • Dual channel safety inputs and bipolar output up to SIL 3, Category 4, PLe • Safety output can be configured for SBC or control via the safety output assembly • Communication for safety I/O data is performed through safety connections that support CIP Safety protocol over an EtherNet/IP network. There are status indicators for each I/O point, see View Status Indicators on page 221. 130 Rockwell Automation Publication 35-UM001G-EN-P - September 2024 F Chapter 6 IMPORTANT Safety Functions The Allen-Bradley® Lifeline™ 5 cable pull switches are compatible with Armor PowerFlex drives that use firmware revisions 2.003 and above. The switches are not compatible with Armor PowerFlex drives that use firmware revisions 2.002 and below. For an alternative on drives with the older firmware revisions, see the Lifeline 4 cable pull switches with the 5-pin, M12 option. To achieve the same safety ratings as the Lifeline 5 switches, the Armor PowerFlex safety input configuration requires both test outputs to be configured as Pulse Test, and both inputs to be configured as Pulse Test, when using Lifeline 4 switches. Safe State The following are the safe states of the Armor PowerFlex safety I/O: • Safety outputs from network data: OFF (single channel and dual channel equivalent) • Safety input data to network: OFF (single channel and dual-channel equivalent) • Safety input data to network: OFF/ON for input channels n/n+1 (dual-channel complimentary, See Dual Channels, Complementary on page 134 for additional details) The safety I/O is designed for use in applications where the safe state is the off state. Safety Input Features • • • • • • • • Safety devices, such as emergency stop push buttons, gate switches, and safety light curtains, can be connected. Dual-channel mode evaluates consistency between two input signals (channels), which allows use of the module for safety Category 3 and 4 and in applications that are rated up to and including Performance Level e/SIL 3 when both channels’ Point Mode configurations are set to Safety Pulse Test. Single-channel mode evaluates one input signal (channel), which allows use of the module for safety Category 2 and in applications that are rated up to and including Performance Level d/SIL 2 when the channel's Point Mode configuration is set to Safety Pulse Test. You can configure a discrepancy time to control how long two channels are allowed to be discrepant before a fault is declared. An external wiring short-circuit check is possible when inputs are wired in combination with test outputs. The drive must be wired in combination with test outputs when this function is used. Independently adjustable on- and off-delays are available per channel. Separate test outputs are provided for short-circuit detection of a safety input or inputs. • Power (24V) can be supplied to devices, such as safety sensors. • Test outputs can be configured as standard outputs. A test output can optionally be used in combination with a safety input for short-circuit detection. To make use of this feature, configure the test output as a pulse test source and configure the safety input as ‘Used with Test Output’. Test Output 0 is associated with SI0 and SI2. Test Output 1 is associated with SI1 and SI3. IMPORTANT There are a total of two test outputs, test output 0 and test output 1. You can configure which pair of safety inputs use the test output when applied in CIP Safety. In CIP Safety mode, you must ensure that the test output 0 and 1 are correctly wired on the safety input connector that is assigned in the configuration (See Configure Safety Inputs on page 198). Rockwell Automation Publication 35-UM001G-EN-P - September 2024 131 Chapter 6 Safety Functions Safety Input Operation Safety inputs are used to monitor a safety input device and can be configured as single or dual channel inputs. They also support configuration of on- and off-delay times. A configurable latch error time allows you to specify the minimum amount of time that a safety input alarm is reported. Single-channel Mode (Safety Inputs) The next paragraph describes the status and value that the I/O subsystem reports for normal and alarm states. In normal operation, the I/O value that is reported is the value being read on the input terminal. The I/O status is on. When a fault is detected, the Safety Input value and status are forced Off. The safety input subsystem allows for a configurable time for which an alarm state is held, which is referred to as Input Latch Error Time. In single channel mode, the input latch error time describes the period between when the alarm condition is removed and when the safety input stops reporting the alarm. Figure 68 shows the operation of input latch error time in single channel mode. See Safety Input or Output Fault Recovery on page 146 for information on how to remove an alarm. Figure 68 - Single-channel Mode Safety Input Terminal Safety Input Value Safety Input Status Input Latch Error Time ON OFF ON OFF OK ALARM Alarm Detected Alarm Condition Removed Alarm Cleared Dual-channel Mode and Discrepancy Time (Safety Inputs) To support redundant safety devices, the consistency between signals on two input points can be evaluated, which is referred to as dual-channel operation. Two modes are available when using dual-channel inputs: equivalent and complementary. When using either dual-channel input mode, the time from when a discrepancy is created and when the discrepancy is reported can be configured, which is referred to as Discrepancy Time. The configured discrepancy time is 0 (deactivated)…65,535 ms in increments of 1 ms. 132 IMPORTANT The dual-channel function is used with two consecutive inputs that are paired together, this process starts at an even input number, such as inputs 0 and 1; 2 and 3; and so on. IMPORTANT Do not set the discrepancy time longer than necessary. The purpose of the discrepancy time is to allow for normal differences between contact switching when demands are placed on safety inputs. For discrepancy checking to operate correctly, only one demand on the safety input is expected during the discrepancy time. If the discrepancy time is set too high, and multiple demands occur during this time, then both safety input channels will alarm. Rockwell Automation Publication 35-UM001G-EN-P - September 2024 Chapter 6 Safety Functions Dual-channel, Equivalent In Equivalent mode, both inputs of a pair must be in the same (equivalent) state. When a transition occurs in one channel of the pair before the transition of the second channel of the pair, a discrepancy occurs. If the second channel transitions to the appropriate state before the discrepancy time elapses, the inputs are considered equivalent. If the second transition does not occur before the discrepancy time elapses, the channels transition to the alarm state. In the fault state, the input and status for both channels are set low (Off). When configured as an equivalent dual pair, the data bits for both channels are sent to the controller as equivalent, both high or both low. Figure 69 - Equivalent, Normal Operation and Fault Detection (Not to Scale) Normal Operation Safety Input 0 Terminal ON OFF Safety Input 1 Terminal ON OFF Safety Input 0 Value ON OFF Safety Input 1 Value ON OFF Dual Channel Status OK ALARM Alarm Operation Discrepancy Time Discrepancy Time Safety Input 0 Terminal ON OFF Safety Input 1 Terminal ON OFF Safety Input 0 Value ON OFF Safety Input 1 Value ON OFF Dual Channel Status OK ALARM Rockwell Automation Publication 35-UM001G-EN-P - September 2024 Alarm Detected 133 Chapter 6 Safety Functions Dual Channels, Complementary In Complementary mode, the inputs of a pair must be in the opposite (complementary) state. When a transition occurs in one channel of the pair before the transition of the second channel of the pair, a discrepancy occurs. If the second channel transitions to the appropriate state before the discrepancy time elapses, the inputs are considered complementary. If the second transition does not occur before the discrepancy time elapses, the channels transition to the alarm state. The alarm state of complementary inputs is the even-numbered input that is turned Off and the odd-numbered input turned On. Note that if faulted, both channel status bits are set low. When configured as a complementary dual-channel pair, the data bits for both channels are sent to the controller in complementary, or opposite states. Figure 70 - Complementary, Normal Operation and Fault Detection (not to scale) Normal Operation Safety Input 0 Terminal ON OFF Safety Input 1 Terminal ON OFF Safety Input 0 Value ON OFF Safety Input 1 Value ON OFF Dual Channel Status OK ALARM Discrepancy Time Alarm Operation Safety Input 0 Terminal ON OFF Safety Input 1 Terminal ON OFF Safety Input 0 Value ON OFF Safety Input 1 Value ON OFF Dual Channel Status OK ALARM Discrepancy Time Alarm Detected Input Delays Each safety input has a configurable filter time for sampling the input. Both the onoff and offon filter values can be configured. 134 Rockwell Automation Publication 35-UM001G-EN-P - September 2024 Chapter 6 Safety Functions Off to On Delay On-delay—An input signal is treated as Logic 0 during the on-delay time (0…65,535 ms, in increments of 1 ms) after the rising edge of the input contact. The input turns on only if the input contact remains on after the on delay time has elapsed. This setting helps prevent rapid changes of the input data due to contact bounce. Figure 71 - On-delay Input Signal ON OFF Safety Input Network Data ON OFF On-delay On to Off Delay Off-delay—An input signal is treated as Logic 1 during the off-delay time (0…65,535 ms, in increments of 1 ms) after the falling edge of the input contact. The input turns off only if the input contact remains off after the off delay time has elapsed. This setting helps prevent rapid changes of the input data due to contact bounce. Figure 72 - Off-delay Input Signal Safety Input Network Data ON OFF ON OFF Off-delay Using a Test Output with a Safety Input A test output can be used in combination with a safety input for short circuit, cross-channel, and open-circuit fault detection. Configure the test output as a pulse test source and associate it to a specific safety input. Figure 73 - Test Output Wiring Example Safety Input 2 1 1 - Test Output 1 2 - Safety Input 1 3 - Input Common 4 - Safety Input 0 5 - Test Output 0 5 4 3 Socket View Figure 74 - Test Pulse in a Cycle On OUT X Y Off The pulse width (X) is typically 500 µs. The pulse period (Y) is typically 300 ms. The relation between pulse period and width is fixed. Rockwell Automation Publication 35-UM001G-EN-P - September 2024 135 Chapter 6 Safety Functions When the external input contact is closed, a test pulse is output from the test output terminal to diagnose the field wiring and input circuitry. By using this function, short-circuits between inputs and 24V power, and between input signal lines and open circuits can be detected. See Figure 75. Figure 75 - Short-circuit between Input Signal Lines 24V +24V (A3) COM (A2) 24V 0V T0 External Contact IN0 Short-circuit between Input Signal Lines and Power Supply (positive side) T1 External Contact IN1 Short-circuit between Input Signal Lines IMPORTANT Depending on the targeted SIL, Category/PL and the safety application, fault exclusions for short circuits between any two conductors/cables may be necessary. See ISO 13849-2, Annex D for additional information. Safety Input Status Data The Safety Input data can be monitored through: • Safety Input Assembly • Message Instruction IMPORTANT Only the Safety Input Value and Status in the Safety Input Assembly can be considered safety data. Input values that are read through CIP messages are not safety data. Do not use standard inputs for safety purposes. The following Safety Input data is available: • Safety Input Status • Safety Input Value (Data) • Safety Input Valid Each safety input point reports its own status, value, and valid attributes. 136 Rockwell Automation Publication 35-UM001G-EN-P - September 2024 Chapter 6 Safety Functions Table 41 shows the relation between physical Safety Input terminal states, and the data and status reported by the Safety Input subsystem. Table 41 - Terminal Safety Input Status and Controller I/O Data Input Terminal Dual-channel Mode Dual-channels, Equivalent Dual-channels, Complementary IN0 IN1 OFF OFF ON ON OFF OFF ON ON OFF ON OFF ON OFF ON OFF ON Controller Input Data and Status Safety Input 0 Safety Input 1 Safety Input 0 Safety Input 1 Data Data Status Status OFF OFF ON ON OFF OFF OFF OFF OFF OFF OFF OFF ON ON ON ON OFF OFF OFF OFF OFF ON ON ON ON OFF ON ON OFF OFF OFF OFF Dual-channel Resultant Data Dual-channel Resultant OFF OFF OFF ON OFF ON ON OFF Normal Alarm Alarm Normal Alarm Normal Normal Alarm Safety Input Status The safety input status indicates whether an alarm is present in the safety input point. The safety input status is provided in the safety input assembly, as shown in Table 42. Table 43 describes the attributes for reading the safety status via CIP messaging. Table 42 - Safety Input Assembly Tags for Safety Input Status Safety Input Assembly Tag Name (safety controller) Type/[bit] Description devicename:SI.InputStatus SINT devicename:SI.In00Status [4] devicename:SI.In01Status [5] devicename:SI.In02Status [6] devicename:SI.In03Status [7] A collection of safety input values and status for each safety input Status of Safety Input 0 0 = Alarm 1 = OK Status of Safety Input 1 0 = Alarm 1 = OK Status of Safety Input 2 0 = Alarm 1 = OK Status of Safety Input 3 0 = Alarm 1 = OK Table 43 - MSG Configuration for Safety Input Status Service Code Class Instance Data Type 0x0E 0x3D i+1 USINT Get attribute single Safety Discrete Input Point Object Where i is the number of the safety input Attribute 0x4 4 (decimal) Safety Status 0 = Alarm 1 = OK Rockwell Automation Publication 35-UM001G-EN-P - September 2024 137 Chapter 6 Safety Functions Safety Input Value The safety input value is the value of the input after safety and on/off delay evaluations when the safety input is not in the alarm state. If the safety input is in the alarm state, this value will always be 0. The safety input value is provided in the safety input assembly, as shown in Table 44. Table 45 describes the attributes for reading the safety value via CIP™ messaging. Table 44 - Safety Input Assembly Tags for Safety Input Values Safety Input Assembly Tag Name (safety controller) Type/[bit] Description devicename:SI.InputStatus SINT devicename:SI.In00Data [0] devicename:SI.In01Data [1] devicename:SI.In02Data [2] devicename:SI.In03Data [3] A collection of safety input values and status for each safety input Value of Safety Input 0 0 = OFF 1 = ON Value of Safety Input 1 0 = OFF 1 = ON Value of Safety Input 2 0 = OFF 1 = ON Value of Safety Input 3 0 = OFF 1 = ON Table 45 - MSG Configuration for Safety Input Value Service Code Class Instance Data Type 0x0E 0x3D i+1 USINT Get attribute single Safety Discrete Input Point Object Where i is the number of the safety input Attribute 0x7 7 (decimal) Safety Input Logical Value 0 = OFF 1 = ON Safety Input Valid When set, the safety input valid attribute indicates that the safety input is configured for safety use and producing valid data. If this value is not set, the data that is associated with the safety input is no longer valid safety data. IMPORTANT 138 The Safety Input Valid attribute should be checked before using safety input data in a safety application. Rockwell Automation Publication 35-UM001G-EN-P - September 2024 Chapter 6 Safety Functions The safety input valid attribute is provided in the safety input assembly, as shown in Table 46. Table 47 describes the attributes for reading the safety value via CIP messaging. Table 46 - Safety Input Assembly Tags for Safety Input Valid Safety Input Assembly Tag Name (safety controller) Type/[bit] Description devicename:SI.IOSupport SINT A collection of bits that describe safety IO functionality devicename:SI.In00Valid [0] Safety Input 0 Valid 0 = Data invalid 1 = Data valid devicename:SI.In01 Valid [1] Safety Input 1 Valid 0 = Data invalid 1 = Data valid devicename:SI.In02 Valid [2] Safety Input 2 Valid 0 = Data invalid 1 = Data valid devicename:SI.In03 Valid [3] Safety Input 3 Valid 0 = Data invalid 1 = Data valid Table 47 - MSG Configuration for Safety Input Valid Service Code Class Instance Data Type 0x0E 0x3D i+1 USINT Get attribute single Safety Discrete Input Point Object Where i is the number of the safety input Attribute 0x64 100 (decimal) Safety Input Valid 0 = Data invalid 1 = Data Valid Table 48 - Safety Input Specifications Input Type IEC 61131-2 (input type) Voltage, on-state Voltage, off-state Current, on-state, minimum Current, off-state, maximum Current Sinking Type 3 11…30V DC -3…5V DC 2 mA 1.5 mA Safety Input Alarms The safety input logic can detect configuration, circuit, and discrepancy errors for each safety input. When an error is detected, the associated safety input data is put into the safe state, and the alarm type attribute is set. Configuration Error A configuration error occurs when a safety input’s configuration data is invalid. If this error occurs, check to make sure that the configuration attributes for the safety input are valid. A configuration error can also occur if the safety input is selected for external pulse testing and the associated test output’s configuration is not valid for this mode. Rockwell Automation Publication 35-UM001G-EN-P - September 2024 139 Chapter 6 Safety Functions Circuit Error A circuit error occurs in a safety input when a pulse test fails. There are two types of circuit errors that can be reported: • Internal Circuit Error - An internal circuit error occurs when an internal pulse test fails. This means that circuitry inside the module has failed. An internal circuit error may not be recoverable; replacing the module may be required. • External Circuit Error - An external circuit error occurs when pulse testing by the safety input’s associated test output fails. This error indicates the input circuitry external to the card has failed. Discrepancy and Dual Channel Errors The discrepancy and dual channel errors are related, as a discrepancy can only occur when the safety input is in dual channel mode. A discrepancy error occurs when one of the dual channel safety inputs is not reporting the expected safety input value. The safety input with the unexpected value reports the discrepancy error. The other associated safety input will also be put in the safe state and report a dual channel error alarm. Determining Safety Input Alarm Type To determine if a safety input is reporting an alarm, examine the safety input’s input status attribute (see Safety Input Status on page 137 for information on accessing this attribute). If the input is reporting an alarm, the alarm type can be accessed through CIP messaging. The safety input alarm type can be read via CIP messaging. See Table 49 for the attributes that are required to read the alarm type. Table 49 - MSG Configuration for Safety Input Alarm Type Parameter Service Code Class Value 0x0E 0x3D Instance i+1 Data Type USINT Attribute 0x6E 110 Description Get attribute single Safety Discrete Input Point Object Where i is the number of the safety input Unsigned integer value Safety Input Alarm Type 0 = No Alarm 1 = Configuration Error 2 = External Circuit Error 3 = Internal Circuit Error 4 = Discrepancy Error 5 = Dual Channel error Safety Input Alarm Recovery If an error is detected, the safety input data remains in the off state. Follow this procedure to activate the safety input data. 1. Remove the cause of the error. 2. Place the safety input (or safety inputs if in dual channel mode) into the safe state. The safety input status turns on (alarm cleared) after the input-error latch time has elapsed. If the latch error time has expired, but the safety input is not yet in the safe state, the alarm will not be cleared. Once the safety input is in the safe state, the alarm will clear immediately. 140 Rockwell Automation Publication 35-UM001G-EN-P - September 2024 Chapter 6 Safety Functions Safety Output Operation The safety outputs can operate only in dual channel bipolar mode. The safety output can also be configured to run pulse test diagnostics. The safety output assembly controls the bipolar output only when the drive is not using the SBC function. If the SBC function is used, it controls the output. Safety Output Features • • • • Current sourcing/current sinking-bipolar pair Dual-channel mode provides redundant control by using two output signals (channels), which allows use of the module for safety Category 4, and applications that are rated up to and including Performance Level e/SIL 3 when both channels' Point Mode configurations are set to Safety Pulse Test. Safety output can be pulse tested to detect field wiring short circuits to 24V DC. Safety output can be configured for SBC or control via the safety output assembly Dual-channel Mode (Safety Outputs) When the data of both channels is in the on state, and neither channel has an alarm, the outputs are turned on. The status is normal. If an alarm is detected on one channel, the safety output data and individual safety output status turn off for both channels. Figure 76 shows the operation of dual channel outputs under normal and alarm conditions. Figure 76 - Dual-channel Setting (Not to Scale) Normal Operation Safety Output 0 ON OFF Safety Output 1 ON OFF Dual Channel Output Status ON OFF Alarm Operation Safety Output 0 Value ON OFF Safety Output 1 Value ON OFF Dual Channel Output Status ON OFF Rockwell Automation Publication 35-UM001G-EN-P - September 2024 Alarm Detected 141 Chapter 6 Safety Functions In dual-channel mode, the output latch error time describes the period between when the alarm condition is removed and when the dual channel safety output stops reporting the alarm. Figure 77 shows the normal operation of output latch error time in dual channel mode. When one or both of the associated output points have an alarm (such as a Pulse Test Failure), and there is a discrepancy between the two channels, the alarm and discrepancy must be cleared before the latch error timer begins counting. Figure 78 shows this special case operation. See Safety Input or Output Fault Recovery on page 146 for information on how to remove an alarm. Figure 77 - Dual Channel Output Latch Error Behavior Output Latch Error Time Safety Output 0 Value ON OFF Safety Output 1 Value ON OFF Safety Output 0 OK Status ALARM Safety Output 1 Status OK ALARM Alarm Detected Alarm Condition Removed and Output Values in Safe State Alarm Cleared Figure 78 - Dual Channel Output Latch Error Behavior With Alarm and Discrepancy Output Latch Error Time Safety Output 0 Value ON OFF Safety Output 1 Value ON OFF Safety Output 0 OK Status ALARM Safety Output 1 Status OK ALARM Alarm Detected 142 Discrepancy Removed Rockwell Automation Publication 35-UM001G-EN-P - September 2024 Alarm Cleared Chapter 6 Safety Functions Safety Output with Test Pulse When the safety output is on, the safety output can be configured to pulse test the safety output channel. By using this function, you can continuously test the ability of the safety output to remove power from the output terminals of the module. If an error is detected, the safety output data and individual safety output status turn Off. Figure 79 - Test Pulse in a Cycle OUT On X Off Y For the Armor PowerFlex drives, the pulse width (X) is typically 500 µs; the pulse period (Y) is typically 300 ms. IMPORTANT To help prevent the test pulse from causing the connected device to malfunction, pay careful attention to the input response time of the output device. Safety Output Data The safety output data can be monitored through: • Safety input assembly • Message Instruction The following safety output data is available: • Safety output status • Safety output ready • Output monitor value Each safety output point reports its own status, monitor value, and ready attributes. Safety Output Status The safety output status indicates whether an alarm is present in the safety output point. The safety output status is provided in the safety input assembly, as shown in Table 50. Table 51 describes the attributes for reading the safety status via CIP messaging. Table 50 - Safety Input Assembly Tags for Safety Output Status Safety Input Assembly Tag Name (safety controller) Type / [bit] Description devicename:SI.OutputStatus SINT devicename:SI.Out00Status [2] devicename:SI.Out01Status [3] A collection of safety output status, safety output monitor values, and test output status Status of Safety Output 0 0 = Alarm 1 = OK Status of Safety Output 1 0 = Alarm 1 = OK Table 51 - MSG Configuration for Safety Output Status Service Code Class Instance Data Type 0x0E 0x3B i+1 Attribute 0x5 5 (decimal) Get attribute single Safety Discrete Output Point Object Where i is the number of the safety output USINT Safety Status 0 = Alarm 1 = OK Rockwell Automation Publication 35-UM001G-EN-P - September 2024 143 Chapter 6 Safety Functions Table 52 - Safety Output Specifications Attribute Output type Output current Value Bipolar output 1A Test Pulse width 500 µs 300 ms Test Pulse period Safety Output Ready When set, the safety output ready attribute indicates that the safety output is configured for safety use and ready to be commanded. IMPORTANT Check the Safety Output Ready attribute before commanding the safety output. The safety output ready attribute is provided in the safety input assembly, as shown in Table 53. Table 54 describes the attributes for the Safety Output Ready attribute via CIP messaging. Table 53 - Safety Input Assembly Tags for Safety Output Ready Safety Input Assembly Tag Name (safety controller) Type/[bit] Description devicename:SI.IOSupport SINT devicename:SI.Out00Ready [4] devicename:SI.Out01Ready [5] A collection of bits describing safety IO functionality Safety Output 0 Ready 0 = Not Ready 1 = Ready Safety Output 1 Ready 0 = Not Ready 1 = Ready Table 54 - MSG Configuration for Safety Output Ready Service Code Class Instance Data Type 0x0E 0x3B i+1 USINT Get attribute single Safety Discrete Output Point Object Where i is the number of the safety output Attribute Safety Status 0x64 Not Ready 100 (decimal) 01 ==Ready Safety Output Monitor Value IMPORTANT Safety Output Monitor Value is not safety data and has no defined safe state. Use Output Monitor Value for diagnostic purposes only. The output monitor value of a safety output is the value of the output that is read by the module. It is expected that the output monitor value is the same as the commanded safety output value in normal operation. The output monitor value can be used to diagnose output alarms. The output monitor value is provided in the safety input assembly, as shown in Table 55. Table 56 describes the attributes for reading the output monitor value via CIP messaging. 144 Rockwell Automation Publication 35-UM001G-EN-P - September 2024 Chapter 6 Safety Functions Table 55 - Safety Input Assembly Tags for Safety Output Monitor Value Safety Input Assembly Tag Name (safety controller) Type/[bit] Description devicename:SI.OutputStatus SINT devicename:SI.Out00Monitor [0] devicename:SI.Out01Monitor [1] A collection of safety output status, safety output monitor values, and test output status Output Monitor Value of Safety Output 0 0 = OFF 1 = ON Output Monitor Value of Safety Output 1 0 = OFF 1 = ON l Table 56 - MSG Configuration for Safety Output Monitor Value Service Code Class Instance Data Type 0x0E 0x3B i+1 USINT Attribute 0x4 4 (decimal) Get attribute single Safety Discrete Output Point Object Where i is the number of the safety output Unsigned integer value Output Monitor Value 0 = OFF 1 = ON Test Output Operation The test outputs of the Integrated Safety Function module can be configured in the following modes: • Test pulse output. When in test output mode, the test output point operates with a safety input to perform pulse testing on the external safety input circuitry. • Power supply output. In power supply output mode, the output point is forced on, and only shuts off for a critical fault. For safety input and output specifications, see Armor PowerFlex AC Drives Specifications Technical Data, publication 35-TD001. ATTENTION: As soon as the firmware boots and power is supplied to the I/O, the test outputs will turn on if they configured for either Pulse Test or Power Supply. These configured functions are independent of the I/O connections to the module. ATTENTION: If a module with Test Outputs configured as Pulse Test or Power Supply is incorrectly installed in an application where actuators are connected to these Test Output points, the actuators are activated as soon as the firmware boots and power is supplied to the I/O. To help prevent this possibility, follow these procedures. • When installing or replacing a module, be sure that the module is correctly configured for the application or in the out-of-box condition before you apply input power. • Reset modules to their out-of-box condition when removing them from an application. • Be sure that all modules in the replacement stock are in their out-of-box condition. ATTENTION: Do not use test outputs as safety outputs. Test outputs do not function as safety outputs. Rockwell Automation Publication 35-UM001G-EN-P - September 2024 145 Chapter 6 Safety Functions Test Output Specifications Output Type Bipolar Output current 1A Test pulse width 500 µs Test Pulse Period 300 ms Field capacitance, maximum 950 nF Residual voltage, maximum 0.3V Leakage current, maximum 0.1 mA Short circuit protection yes Reaction time from message to <10 ms Output safe, maximum Safety Input or Output Fault Recovery If an error is detected, the safety data remains in the Off state. Follow this procedure to activate the safety data again. 1. Remove the cause of the error. 2. Place the safety input or safety output into the safe state. 3. Allow the input- or output-error latch time to elapse. After these steps are completed, the I/O indicator (red) turns Off. The safety input or output data is now active. IMPORTANT 146 Stuck high faults on safety outputs require a power reset to clear the error. Rockwell Automation Publication 35-UM001G-EN-P - September 2024 Chapter 6 Safety Functions Safety I/O Wiring IMPORTANT The wiring examples that are shown here are not a guarantee of Safety Category and Performance Level ratings. You must perform your own risk assessment to validate the requirements of your system. . Safety Input Internal Wiring Diagram Example Armor PowerFlex Drive Internal Circuitry Unswitched 24V DC Field Wiring Safety VCC_3V3 Test Out 1 Circuit Test 1 Test Output 1 In1 Test Safety VCC_3V3 Unswitched 24V DC Safety µC A Safety Input 1 Safe In1 Circuit In1 Monitor Safe In0 Circuit In0 Monitor Input Common Safety Input 0 Test Output 0 Safety VCC_3V3 Unswitched 24V DC In0 Test Test Out 0 Circuit M12 5-Pin Connector Unswitched 24V DC Safety µC B Test 0 Safety VCC_3V3 Safety Output Internal Wiring Diagram Example Armor PowerFlex Drive Internal Circuitry Safety VCC_3V3 Safety 24V DC Safety Source Out 0 Safety Out 0 Source Circuit Out 1 Safety µC B Out 1 Monitor Safety Sink Out 0 Safety VCC_3V3 Safety 24V DC Safety Out 0 Sink Circuit Out 0 Safety µC A Output Common Out 0 Monitor M12 5-Pin Connector Rockwell Automation Publication 35-UM001G-EN-P - September 2024 147 Chapter 6 Safety Functions Status and Faults Each Safety I/O point has a status LED see I/O Status Indicators on page 221 for details. Safety Input Wiring Examples Connected Devices Reset switch Output Pulse from Output Test Connection No Connect the switch between Test Output 1 and Input 1 Up to Up to Safety Performance Category Level Schematic Diagram Pin 1: Test Output 1 Pin 2: Input 1 Pin 3: Input Common Pin 4: Input 0 Pin 5: Test Output 0 1 2 PLc 4 PLe 4 PLe 2 5 4 Emergency stop switch Door monitor Yes Connect the switch between Test Output 1 and Input 1 and between Test Output 0 and Input 0 3 Pin 1: Test Output 1 Pin 2: Input 1 Pin 3: Input Common Pin 4: Input 0 Pin 5: Test Output 0 1 2 5 4 Pin 1: Test Output 1 - OSSD Safety Device Light Curtain or No Safety Mat Connect Test Output 1 to Device Power and connect Safety Inputs to OSSD device outputs configured as Power Supply(a) Pin 2: Input 1 Pin 3: Input Common Pin 4: Input 0 Pin 5: Test Output 0 not connected 3 1 Light Curtain or Safety Mat + OSSD1 - OSSD2 5 4 (a) You cannot use other Safety Inputs in Test Pulse configuration, when a Test Output is configured for Power Supply. 148 Rockwell Automation Publication 35-UM001G-EN-P - September 2024 2 3 Chapter 6 Safety Functions Safety Output Wiring Examples Connected Devices Output Pulse from Output Test Connection Up to Up to Safety Performance Category Level Schematic Diagram Pin 1: No connection Pin 2: Output 0 (sink) Pin 3: Output Power Common Pin 4: Output 0 (source) Pin 5: Output Power Common Yes - see pulse Connect the switch between Output 0 Drive inductive load testing (sink) and Output 0 IMPORTANT note (source) 4 1 PLe 2 5 4 IMPORTANT 3 Depending on the targeted SIL, Category/PL and the safety application, fault exclusions for short circuits between any two conductors/cables may be necessary. See ISO 13849-2, Annex D for additional information. IMPORTANT IMPORTANT When pulse testing is used to achieve the maximum safety rating (SIL 3 Category 4, PLe) the safety output wiring must be protected against external damage by cable ducting, conduit, armored cable, or other means. See ISO 13849-2:Table D.4, for additional information. Rockwell Automation Publication 35-UM001G-EN-P - September 2024 149 Chapter 6 Safety Functions Replacing an Armor PowerFlex Drive on a Safety Network GuardLogix controllers retain I/O device configuration onboard and are able to download the configuration to the replacement device. IMPORTANT If the Armor PowerFlex drive was used previously, clear the existing configuration before installing it on a safety network by resetting the device to out-of-box condition. See Reset Ownership on page 97. Replacing an Armor PowerFlex drive that sits on an integrated safety network is more complicated than replacing standard devices because of the safety network number (SNN). The device number and SNN constitute the safety device's DeviceID. Safety devices require this more complex identifier to make sure that duplicate device numbers do not compromise communication between the correct safety devices. The SNN is also used to provide integrity on the initial download to the device. Replace an Armor PowerFlex drive in a GuardLogix System When you replace an Armor PowerFlex drive, the replacement device must be configured properly and the replacement Armor PowerFlex drive’s operation be user-verified. ATTENTION: During an Armor PowerFlex drive replacement or functional test, the safety of the system must not rely on any portion of the affected Armor PowerFlex drive. There are two options for Armor PowerFlex drive replacement available on the Safety page of the Controller Properties dialog box in the Logix Designer application: • Configure Only When No Safety Signature Exists • Configure Always Figure 80 - Armor PowerFlex Drive Replacement Options 150 Rockwell Automation Publication 35-UM001G-EN-P - September 2024 Chapter 6 Safety Functions Configure Only When No Safety Signature Exists This setting instructs the GuardLogix controller to automatically configure an Armor PowerFlex drive only when the safety task does not have a safety task signature, and the replacement Armor PowerFlex drive is in an out-of-box condition, meaning that a safety network number does not exist in the Armor PowerFlex drive. If the safety task has a safety task signature, the GuardLogix controller automatically configures the replacement CIP Safety I/O device only if the following is true: • The device already has the correct safety network number. • The device electronic keying is correct. • The node or IP address is correct. For detailed information, see the user manual for your GuardLogix controller. Configure Always When the Configure Always feature is enabled, the controller automatically checks for and connects to a replacement Armor PowerFlex drive that meets the following requirements: • The controller has configuration data for a compatible Armor PowerFlex drive at that network address • The Armor PowerFlex drive is in out-of-box condition mode or has an SNN that matches the configuration ATTENTION: Enable the Configure Always feature only if the entire integrated safety control system is not being relied on to maintain SIL 2/PLd or SIL 3/PLe behavior during the replacement and functional testing of the product. If other parts of the integrated safety control system are being relied upon to maintain SIL 2/PLd or SIL 3/PLe, make sure that the controller’s Configure Always feature is disabled. It is your responsibility to implement a process to make sure proper safety functionality is maintained during device replacement in safety control systems that are not being relied upon for SIL 2/PLd or SIL 3/PLe. See the GuardLogix user manual appropriate for your Logix 5000 controller: • ControlLogix 5580 and GuardLogix 5580 Controllers User Manual, publication 1756-UM543 • CompactLogix 5380 and Compact GuardLogix 5380 Controllers User Manual, publication 5069-UM001 Rockwell Automation Publication 35-UM001G-EN-P - September 2024 151 Chapter 6 Safety Functions Notes: 152 Rockwell Automation Publication 35-UM001G-EN-P - September 2024 Chapter 7 Configure the Armor PowerFlex Drive The Armor PowerFlex drive is configured by using the Studio 5000 Logix Designer application. The drive's operation is based on the settings that are defined in a set of CIP objects and attributes, which you can configure via the user interface in the Logix Designer application. For the list of CIP objects and attributes, see Armor PowerFlex AC Drive CIP Objects and Attributes Reference Data, publication 35-RD001. Install Armor PowerFlex Add-on Profile Download and install the Add-on Profile (AOP) for the Armor PowerFlex drive so that the Studio 5000 Logix Designer application can fully support the features of the Armor PowerFlex drive. Download AOPs from the Product Compatibility Download Center (PCDC) website at rok.auto/pcdc. Create a Logix Designer Project Before you can add the Armor PowerFlex drive, you must create a Logix Designer project that includes a Logix 5000 controller with a connection to the EtherNet/IP network. The Armor PowerFlex has an embedded dual port EtherNet module so there is no need for an optional EtherNet communication module. If you are using integrated Safe Torque Off (STO), drive-based, or controller-based safety functions or the Armor PowerFlex drive’s safety I/O, your system must include an integrated safety controller, see Integrated Safety Functions and Compatible Controllers on page 91. See Additional Resources on page 12, for a listing of integrated safety controller user manuals. Rockwell Automation Publication 35-UM001G-EN-P - September 2024 153 Chapter 7 Configure the Armor PowerFlex Drive Select FactoryTalk Linx Communication The Armor PowerFlex drive requires FactoryTalk® Linx communication. This is selected in the Studio 5000 Logix Designer application. Starting with Studio 5000 version 33.00, the default communication software is set to FactoryTalk Linx. IMPORTANT The current project file must be closed first in the Logix Designer application before changing to FactoryTalk Linx communication, or an error message will pop up that indicates it cannot change communication software. 1. To choose FactoryTalk Linx in Studio 5000 Logix Designer application, click on Communications. 2. Click on Select Communications Software. 3. Click on FactoryTalk Linx. 4. Click OK. 5. Re-open your project. 154 Rockwell Automation Publication 35-UM001G-EN-P - September 2024 Chapter 7 Configure the Armor PowerFlex Drive The pages of configuration dialog boxes that are available in the Logix Designer application vary depending on which version of Armor PowerFlex drive you have and also on the configuration choices you make when you set up your drive. See Table 57. Table 57 - Pages Available Based on the Configured Variant Type Configured Connection Type Standard Only Standard and Safety Safety Only IMPORTANT Page Overview Device Definition Datalinks Input Datalinks Output Quick Start Date and Time Faults and Alarms Predictive Maintenance Motor Control Autotune Encoder Feedback Velocity Control Stop Control Connection Input/Output Configuration Events Overview Device Definition Datalinks Input Datalinks Output Quick Start Date and Time Faults and Alarms Predictive Maintenance Safety Configuration Safety Feedback Scaling Safe Torque Off (STO) Safe Brake Control (SBC) Safe Stop 1 (SS1) Input Configuration Output Configuration Actions Motor Control Autotune Encoder Feedback Velocity Control Stop Control Connection Input/Output Configuration Events Overview Device Definition Date and Time Faults and Alarms Predictive Maintenance Safety Configuration Safety Feedback Scaling Safe Torque Off (STO) Safe Brake Control (SBC) Safe Stop 1 (SS1) Input Configuration Output Configuration Actions Connection For any new entires or modifications that you make to a page, you must click Apply or OK when finished, to save the entered values. A notification dialog box will be displayed, as a reminder. Rockwell Automation Publication 35-UM001G-EN-P - September 2024 155 Chapter 7 Configure the Armor PowerFlex Drive Add an Armor PowerFlex Drive to the Project 1. Right-click the Ethernet network and choose New Module. 2. Select the appropriate Armor PowerFlex option and click Create. Logix Designer Application Information The Logix Designer application contains detailed information for specific configuration fields. Click on the embedded information icons to display information that will assist your configuration process. Configure the Device Definition When the Armor PowerFlex module is first created, the software automatically launches the Device Definition window since the Name and IP Address of the module is the minimal configuration that is needed to create the module. To make any changes to the Device Definition at a later time, you will need to launch Device Definition from the Overview page. 156 Rockwell Automation Publication 35-UM001G-EN-P - September 2024 Chapter 7 Configure the Armor PowerFlex Drive Perform the following steps to enter your device details. 1. Enter values and use pull-down menus to configure the device definition. See Table 58. As you enter values, the Catalog Number field will update accordingly. An “X” will be displayed in the Catalog Number field for values that are irrelevant to the drive configuration. If there is a catalog number or firmware revision mismatch when going online, warning icons will appear in the fields that must be corrected. Table 58 - Device Definition Settings Field Description Name for your Armor PowerFlex drive, which also defines how Control Tags that are Name associated with the drive, are named in the Logix Designer application. Firmware revision for the drive, including major and minor revision levels — The available major firmware revisions in the pull-down menu are dependent on the AOP version that is installed. (See the left-hand side footer of the Logix Designer screen.) Selecting revision 2.000 or later allows access to: Firmware Revision • Datalinks feature, seeConfigure Datalinks on page 159 • Frame size B support • Events configuration, see Configure Events on page 191 • Automatic or Manual EM Brake control, see Configure Electromechanical Brake on page 186 Description Optionally add a description of your Armor PowerFlex drive Indicates that all keying attributes must match to establish Exact Match communication. If any attribute does not match precisely, communication with the device does not occur. Lets the installed device accept the key of the device that is defined in the project, when the installed device can emulate the defined device. With Compatible Module, you can typically replace a device with another device that has the following characteristics: Compatible Keying • Same catalog number (default) • Same or higher Major Revision • Minor Revision as follows: – If the Major Revision is the same, the Minor Revision must be the same or higher. – If the Major Revision is higher, the Minor Revision can be any number. Indicates that the keying attributes are not considered when attempting to communicate with a device. With Disable Keying, Disable Keying communication can occur with a device other than the type specified in the project. Electronic Keying IMPORTANT ATTENTION: Be cautious when using Disable Keying; if used incorrectly, this option can lead to personal injury or death, property damage, or economic loss. We strongly recommend that you do not use Disable Keying. If you use Disable Keying, you must take full responsibility for understanding whether the device being used can fulfill the functional requirements of the application. Changing Electronic Keying attributes online interrupts connections to the device and any devices that are connected through the device. Connections from other controllers can also be broken. If an I/O connection to a device is interrupted, the result can be a loss of data. Rockwell Automation Publication 35-UM001G-EN-P - September 2024 157 Chapter 7 Configure the Armor PowerFlex Drive Table 58 - Device Definition Settings Field Description An exclusive standard I/O connection that lets the standard input and standard output connections be configured for Data or Listen Only connections. The safety input and output connections are set to None. An exclusive safety I/O connection where a programmable Safety Only controller owns the communication channel and provides safety (35S) data and configuration from the safety I/O. The standard input and output connections, if available on the drive, are set to None. Standard and There is a data connection and separate safety connection that Safety provides an exclusive communication channel for standard I/O (35S) and safety I/O data. Type the IP address. This setting must match the IP address that you set on the Armor PowerFlex drive by using one of the methods that are outlined in Set the IP Address on page 69. IP Address - Enter an IP address, subnet mask, and gateway address for the drive. This is the IP address that the controller uses to communicate with the drive. Private Network - Type or select the desired address. This is the IP address that the controller uses to communicate with the drive. Host Name - Type the host name of the host Ethernet drive. Host Name is only active for Standard Only connection. Not Used No safety application — default for standard variant Standard Only (35E or 35S) Connection Ethernet Address Safety Instance Variant Drive Rating Safe Stop Only(1) Single Feedback Monitoring(1) Standard (E) Safety (S) 1 HP (0.75 kW) 2 HP (1.5 kW) 3 HP (2.2 kW) 5 HP (4 kW)(2) STO function and Timed SS1 Safe Stop functions are available. Primary feedback is used in the safety object for safe monitoring. Standard drive Integrated Safety drive Power rating for drive 7.5 HP (5.5 kW)(2) Power Supply EM Brake 10 HP (7.5 kW)(2) Internal 24V DC External 24V DC Not Equipped Equipped Auxiliary/control power is supplied by the drive. You are supplying the power supply for the auxiliary/control power The drive does not have a mechanical brake option The drive has the mechanical brake control option (1) Only available when Connection type is Safety Only or Safety and Standard. (2) Only available when the Revision is set to 2.000 or higher. IMPORTANT For an Armor PowerFlex drive with safety (35S), the safety and standard connections can both be managed by one Safety controller, or the safety connection can be managed by a Safety controller and the standard connection managed by a second controller. For example, a GuardLogix controller manages the safety connection and a CompactLogix controller manages the standard connection. In the case that one Safety Controller will manage the safety connection and another controller will manage the standard connection, the safety connection must be done first and then, the standard connection. If the standard connection from a controller is done first, the safety connection from the different Safety Controller will be rejected. 2. After the values are entered, click OK. 158 Rockwell Automation Publication 35-UM001G-EN-P - September 2024 Chapter 7 Configure the Armor PowerFlex Drive Configure Datalinks A datalink is a custom controller's tag that can be assigned to a user-defined attribute. Once created, it is added to the tag database and automatically transferred between the controller and the drive. It allows the specified attribute value to be read or written without using explicit message instructions. Armor PowerFlex drives use datalinks to transfer data, to and from the controller. When an I/O connection that includes datalinks is active, the datalinks being used are locked and cannot be changed until the I/O connection becomes idle or inactive. Use datalinks when you need to change a value of a parameter frequently. Because when you use a datalink to change a value, the value is not written to the Non-Volatile Storage (NVS). Instead, the value is stored in volatile memory and lost when the drive loses power. IMPORTANT Datalinks are only available if you select drive firmware revision 2.000 or higher. Input datalink stores the current value of user-defined drive's status attribute. Data is produced by the drive and consumed by the controller (data is sent from the drive to the controller). Output datalink modifies the value of user-defined drive's control attribute. Data is produced by the controller and consumed by the drive (data is sent from the controller to the drive). Datalink names are predefined and can be changed using Logix Designer's aliasing feature. Requested Packet Interval value specifies the period at which the data is updated. Available Datalinks are as follows: • 8 configurable boolean datalinks for standard inputs • 4 configurable real floating-point datalinks for standard inputs • 8 configurable boolean datalinks for standard outputs • 4 configurable real floating-point datalinks for standard outputs For details about the Armor PowerFlex attributes, see the Armor PowerFlex AC Drives CIP Objects and Attributes Reference Data, publication 35-RD001. Perform the following steps to set up datalinks. 1. Click Datalinks Input or Datalinks Output. 2. Click Add Datalink to select a specific datalink. See Table 59 for a listing of datalinks. Table 59 - Datalinks Datalinks Input DC injection braking is on Encoder Feedback Data is Valid Motor current exceeds overload current limit Motor thermal capacity is utilized above safe limit Actual Acceleration Time Reference used by the drive [s] Actual Deceleration Time Reference used by the drive [s] Actual S-Curve Reference used by the drive [%] Rockwell Automation Publication 35-UM001G-EN-P - September 2024 Datalinks Output Acceleration / Deceleration Control Switch Switch between Current Limit 1 and 2 values Disable predefined Keypad Functions Dynamic Acceleration Time Reference [s] Dynamic Deceleration Time Reference [s] Dynamic S-Curve Reference [%] 159 Chapter 7 Configure the Armor PowerFlex Drive Table 59 - Datalinks Datalinks Input Datalinks Output Minimum measured temperature of motor output heatsink [°C] Maximum measured temperature of motor output heatsink [°C] Dynamic Brake is active Encoder Feedback is Faulted Flying start is currently active Output Point 0 Status Output Point 1 Status Input Point 0 Status Input Point 1 Status Input Point 2 Status Input Point 3 Status IO Point 0 Status IO Point 1 Status Amount of current that is producing torque [A] 160 Rockwell Automation Publication 35-UM001G-EN-P - September 2024 Chapter 7 Configure the Armor PowerFlex Drive Your configured datalinks are displayed in a table that is located below the Add Datalink button. You can remove or rearrange datalinks by following the listed instructions. The Logix Designer application calculates in real time, the remaining slots available for datalinks. Once profile configuration is applied, the datalinks are created in Logix Designer’s Controller Tag section. For more information, see Auto-generated Tags on page 205. View or Generate a Safety Network Number The Logix Designer application automatically assigns a Safety Network Number (SNN) to each Armor PowerFlex safety drive as it is added to the project. The SNN is a time-based number that uniquely identifies subnets across all networks in the safety system. All Armor PowerFlex safety drives in a same system use the same SNN by default. Manual manipulation of an SNN is required in the following situations: • If safety consumed tags are used • If the project consumes safety input data from a device whose configuration is owned by some other device • If a safety project is copied to another hardware installation within the same routable safety system If an SNN is assigned manually, the SNN has to be unique. IMPORTANT If you assign an SNN manually, make sure that the system expansion does not result in duplication of SNN and node address combinations. An alert message appears if your project contains duplicate SNN and node address combinations. You can still verify the project, but we recommend that you resolve the duplicate combinations. To edit the SNN, follow these steps. 1. To open the Safety Network Number dialog box, click Edit, (to the right of the Safety Network Number), in the Device Definition dialog box. 2. Select either Time-based or Number-based. Rockwell Automation Publication 35-UM001G-EN-P - September 2024 161 Chapter 7 Configure the Armor PowerFlex Drive 3. 4. 5. 6. If you select Number-based, enter a value from 1…9999 decimal. Click Set. Click OK to close the Safety Network Number dialog box. Click OK again, to close the Device Definition dialog box. If needed, the Device Definition dialog box can be reaccessed via the Overview page, until the configuration is applied to the project. Enable Inhibit Module Connection for Quick Start Once you create a new module and click OK on the Device Definition page, the Logix Designer application will prompt you to inhibit the connection. This is a requirement if you are planning to run Quick Start. Quick Start Quick Start is an optional wizard that allows you to quickly set up the drive and test the motor. Quick Start is only available if you are online and a connection between the Armor PowerFlex drive and the programmable controller is inhibited. Perform the following steps to run Quick Start. 1. Click Quick Start. Certain conditions must be met before you can run Quick Start. The following message will pop up, indicating what conditions still need to be met before the Quick Start can be run. In this example, the project is offline. One of the required conditions is to be online with the project. 162 Rockwell Automation Publication 35-UM001G-EN-P - September 2024 Chapter 7 Configure the Armor PowerFlex Drive Quick Start Offline Message After you are online, the following message is displayed. You must meet the remaining conditions to enable the Run Quick Start button. Quick Start Online Message 2. Click Run Quick Start. Data that is written during the Quick Start procedure is immediately saved to the Armor PowerFlex drive. 3. The Quick Start consists of three pages: - Motor Data - Direction Test - Autotune Follow the prompts of each of the pages sequentially, to complete the Quick Start. Rockwell Automation Publication 35-UM001G-EN-P - September 2024 163 Chapter 7 Configure the Armor PowerFlex Drive Motor Data Page 4. Starting with the Motor Data page, enter input data from the motor nameplate. The motor nameplate data is immediately applied to the drive and saved to the project. This means that once you do direction tests, the drive uses the actual provided motor data instead of default values. 5. Click Calculate Pole Count and enter the number of poles (2…40). 6. Click Next, when finished. This will open the Direction Test page. Direction Test Page 7. As prompted, enter a Jog Reference (preferably a slow speed) and click the Jog button to confirm that the motor is moving in the correct direction. Adjust if necessary. 164 Rockwell Automation Publication 35-UM001G-EN-P - September 2024 Chapter 7 Configure the Armor PowerFlex Drive 8. If necessary, adjust the Motor Polarity field, or swap two of the motor cables to change the motor rotation direction. Both Jog Reference and Motor Polarity are applied to the drive immediately. You do not need to apply it manually (by pressing OK or Apply). WARNING: Before swapping motor cables, take appropriate precautions to remove power to the motor. 9. Once the motor is rotating in the correct direction, click Next to access the Autotune page. See Run Autotune on page 173. Rockwell Automation Publication 35-UM001G-EN-P - September 2024 165 Chapter 7 Configure the Armor PowerFlex Drive Configure Motor Control Motor control configuration is concerned with the configuration of the control mode and control method. Basic motor control involves the control of the state of a connected motor. The state can either be stopped (no power applied to motor) or running (power applied to motor). Basic motor control also allows the direction of motion of the motor to be controlled. When the Armor PowerFlex drive is configured for standard and safety or standard only connections, the following categories are available in the Module Properties window, for motor configuring operation: • Motor Control • Velocity Control • Encoder Feedback • Stop Control Click Motor Control. - 166 Rockwell Automation Publication 35-UM001G-EN-P - September 2024 Chapter 7 Configure the Armor PowerFlex Drive Configure Motor Control Mode Control mode specifies what parameters the motor control in the device is controlling. Basically it indicates the property or properties of the motor output that are being actively managed by the motor control algorithms. Armor PowerFlex drives use velocity control. 1. On the Motor Control page, choose a Motor Control Mode. Motor Control Mode Description If you choose this mode, you can adjust the Frequency control settings as described in Volts/Hertz (V/Hz) Voltz/Hertz Control Mode See Volts/Hertz Control Mode. The motor is controlled using current feedback, assuming that the total current is the sum of the torque- and flux-producing components. In this mode, you cannot Sensorless Vector (SVC) vector adjust the Frequency Control settings. See Configure Slip Droop Compensation, for the next steps. A high-speed bandwidth regulator and adaptive controller are used to provide continuous regulation of the motor speed and improved overall control. It is Velocity Vector (VVC) recommended to use an encoder when using VVC mode. In this mode, you cannot adjust the Frequency Control settings. See Configure Slip Droop Compensation, for next steps. In this mode, when steady state speed is achieved, the economizer becomes active and automatically adjusts the drive output voltage based on the applied load. By matching output voltage to applied load, the motor efficiency is optimized. Reduced load commands a reduction in motor flux current. The feature is inactive during Sensorless Vector (SVC) acceleration, deceleration or any load changes. Economizer Applications using a PID control scheme, where the speed of the motor may continuously vary according to the output of the PID, will not benefit from this feature. We also do not recommended to use the Economizer on highly dynamic applications, as it may cause delays in motor (torque) reaction. In this mode, Frequency Control settings cannot be adjusted. Volts/Hertz Control Mode The Volts/Hertz Control Mode uses a a fixed relationship between frequency and voltage, forming what is known as a "Volts per Hertz" curve. When you select Volts/Hertz mode, you can adjust the Frequency Control settings to influence the curve. Figure 81 - Volts per Hertz Curve Example Voltage, max Base Voltage (nameplate) Break Voltage Start Boost Break Frequency Base Frequency, (nameplate) Frequency, max 2. On the Motor Control page, choose a Frequency Control method. Boost Select Types Custom V/Hz Variable Torque Constant Torque Description Custom V/Hz allows a wide variety of patterns for the V/Hz ratio. The default configuration is a straight line from zero to rated voltage and frequency. The volts/ hertz ratio can be changed to provide increased torque performance when required. See Figure 81. Variable frequency control selects a curve suitable for variable torque loads such as fans and pumps. This type of curve has no starting / acceleration boost. See Figure 82 on page 168. Constant frequency control selects a curve suitable for constant torque loads such as conveyors and compressors. See Figure 83 on page 168. Rockwell Automation Publication 35-UM001G-EN-P - September 2024 167 Chapter 7 Configure the Armor PowerFlex Drive Figure 82 - Variable Frequency Example Voltage, max Voltage Base Voltage (nameplate) Start Boost Frequency (Hz) Base Frequency, (nameplate) Frequency, max Figure 83 - Constant Frequency Example [Maximum Voltage] [Start Boost] [Break Voltage] Voltage [Rated Voltage] [Break Frequency] [Minimum Freq] [Rated Frequency] Frequency [Maximum Freq] Frequency control parameters are only enabled if you select Custom V/Hz Boost Select type, otherwise, they are disabled. See Table 60 on page 169 to help you set the frequency control values. 168 Rockwell Automation Publication 35-UM001G-EN-P - September 2024 Chapter 7 Configure the Armor PowerFlex Drive Table 60 - Frequency Control Parameters Frequency Control Value Description This setting redefines the Volts/Hz curve. It is used to create additional torque for breakaway from zero speed and acceleration of heavy loads at lower speeds. The boost voltage is only applied until the specified break voltage/frequency point on the curve is reached. The range is 0…115 V, with a default setting of 11.5V. Type a value to set the output voltage of the drive at the Break Frequency where boost ends. This setting is used to increase the slope of the lower portion of the Volts / hertz curve, providing additional torque. The range is 0…460 V, with a default setting of 115V. Type a value to set the output frequency of the drive device at the Break Voltage where boost ends. Used to increase the slope of the lower portion of the Volts / hertz curve, providing additional torque. The range is 0.0…500.0 Hz, with a default setting of 15.0 Hz. Start Boost Voltage Break Voltage Break Frequency Autotune The Armor PowerFlex drive provides an Autotune feature to obtain proper motor tuning data to provide optimal velocity control performance for Sensorless Vector or Velocity Vector control modes. Autotune does not adjust the performance of V/Hz control, so do not run it for this motor control mode. See Run Autotune on page 173 for instructions on performing the Autotune application. The motor tuning data can also be entered manually with values that are available from the motor manufacturer. Configure Motor Polarity Choose either Normal or Inverted motor polarity and enter a Maximum PWM frequency value. Attribute Range Description This setting limits the carrier frequency of the PWM output Maximum PWM Frequency 2000…16,000 Hz waveform. Figure 84 on page 169 provides derating guidelines that are based on the PWM frequency setting. Configure Slip Droop Compensation Choose either Slip or Droop compensation type and enter a value for Full Load Compensation. Attribute Range Full Load Compensation 0…600 RPM Description This setting compensates for the inherent slip or droop in an induction motor. This speed is either added (for slip) or subtracted (for droop) to the commanded output frequency based on motor current. Figure 84 - Maximum PWM 120 Current Ratio [%] 100 80 60 40 20 0 2 4 6 8 10 12 14 16 18 Carrier Frequency [kHz] Rockwell Automation Publication 35-UM001G-EN-P - September 2024 169 Chapter 7 Configure the Armor PowerFlex Drive Configure Motor Nameplate IMPORTANT This section is for offline entry of Motor Nameplate Data. If you already entered Motor Nameplate Data via Quick Start, it is already saved and you do not need to re-enter it. From the Motor Control page, enter Motor Nameplate values based on your system configuration. Enter motor nameplate data for Voltage, Frequency, and Full Load Current. IMPORTANT The motor nameplate values entered must match the actual characteristics of the connected motor. Do not use the default values if they do not match. If these values are incorrect, poor motor control performance, faults, and other undesired behavior can result. Size: 1 Hp (35S-6D1-*, 35E-6D1-*) Motor Nameplate Voltage Frequency Rated Speed Rated Power Pole Count Full Load Amps rms Minimum 20V AC 0 Hz 0 RPM 0 kW 2 0.0652 A Maximum 460V AC 500 Hz 24,000 RPM 0.75 kW N/A 2.3 A Default 460V AC 60 Hz 1750 RPM 0.75 kW 4 2.3 A Maximum 460V AC 500 Hz 24,000 RPM 1.5 kW N/A 4.0 A Default 460V AC 60 Hz 1750 RPM 1.5 kW 4 4.2 A Maximum 460V AC 500 Hz 24,000 RPM 2.2 kW N/A 6.0 A Default 460V AC 60 Hz 1750 RPM 2.2 kW 4 6.0 A Size: 2 Hp (35S-6D2-*, 35E-6D2-*) Motor Nameplate Voltage Frequency Rated Speed Rated Power Pole Count Full Load Amps rms Minimum 20V AC 0 Hz 0 RPM 0 kW 2 0.0652 A Size: 3 Hp (35S-6D3-*, 35E-6D3-*) Motor Nameplate Voltage Frequency Rated Speed Rated Power Pole Count Full Load Amps rms 170 Minimum 20V AC 0 Hz 0 RPM 0 kW 2 0.0652 A Rockwell Automation Publication 35-UM001G-EN-P - September 2024 Chapter 7 Configure the Armor PowerFlex Drive Size: 5 Hp (35S-6D4-*, 35E-6D4-*) Motor Nameplate Voltage Frequency Rated Speed Rated Power Pole Count Full Load Amps rms Minimum 20V AC 0 Hz 0 RPM 0 kW 2 0.0652 A Maximum 460V AC 500 Hz 24,000 RPM 3.7 kW N/A 2.3 A Default 460V AC 60 Hz 1750 RPM 3.7 kW 4 10.5 A Maximum 460V AC 500 Hz 24,000 RPM 5.6 kW N/A 4.0 A Default 460V AC 60 Hz 1750 RPM 5.6 kW 4 13 A Maximum 460V AC 500 Hz 24,000 RPM 7.5 kW N/A 6.0 A Default 460V AC 60 Hz 1750 RPM 7.5 kW 4 17 A Size: 7.5 Hp (35S-6D5-*, 35E-6D5-*) Motor Nameplate Voltage Frequency Rated Speed Rated Power Pole Count Full Load Amps rms Minimum 20V AC 0 Hz 0 RPM 0 kW 2 0.0652 A Size: 10 Hp (35S-6D6-*, 35E-6D6-*) Motor Nameplate Voltage Frequency Rated Speed Rated Power Pole Count Full Load Amps rms Minimum 20V AC 0 Hz 0 RPM 0 kW 2 0.0652 A Rockwell Automation Publication 35-UM001G-EN-P - September 2024 171 Chapter 7 Configure the Armor PowerFlex Drive Configure Motor Protection 1. From the Motor Control page, enter the values for Motor Protection. See Set Date and Time on page 227, for synchronization procedure. Attribute Range Assume Motor Cold Description The value of the Thermal Capacity Utilized attribute is reset to 0 on power up. This assumes that the motor is fully cool. The value of the Thermal Capacity Utilized attribute is saved at Use Saved down and restored on power up. This assumes that the motor Thermal Overload Power Thermal Capacity power has not cooled down at all while the product was off. Up Behavior The value of the Thermal Capacity Utilized attribute is saved at Use Motor power down. The value is then reduced on power up to account for Cooling Model motor cooling while the unit was powered down, based on the amount of time the unit was powered down. Overload Current 0…34.0(1) A Current Limit 1 Current Limit 2 0.00…25.5(1) A Derate Frequency 0…60 Hz Set the overload current to the maximum allowable current. Configure the Current Limit, which sets the maximum motor output current that is allowed before current limiting occurs. The drive uses Current Limit 1 as default and ignores Current Limit 2. However, you can switch between them by using a Message Instruction or by using the datalink: Switch Between Current Limit 1 and Current Limit 2 (See Configure Datalinks on page 159). Set the Derate Frequency, which lets the thermal capacity be reduced when the frequency being output to the motor is below this value. (1) The maximum range value will vary based on the Drive Rating that is selected in the Device Definition. Derating Use the Load vs. Temperature graph, Figure 85, to derate for altitudes from 0…1000 m (0…3300 ft). Figure 85 - Load vs. Temperature Derating for 0…1000 m (0…3300 ft) 120 100 Load [%] 80 60 40 20 0 -25 -5 15 35 55 75 Temperature [°C] If the drive is used above 1000 m (3300 ft): • Derate the maximum ambient temperature by 5 °C (9 °F) for every additional 1000 m (3300 ft), above the nominal 1000 m (3300 ft). Or • Derate the output current by 10% for every additional 1000 m (3300 ft), above the nominal 1000 m (3300 ft). See Figure 86. 172 Rockwell Automation Publication 35-UM001G-EN-P - September 2024 Chapter 7 Configure the Armor PowerFlex Drive 0 2000 Figure 86 - Derating Curves for High Altitude % Rated Current 120 110 100 90 80 70 60 50 40 60 Ambient Temperature [ °C] 50 40 30 0 1000 2000 3000 4000 4800 20 1000 Altitude [m] 3000 4000 4800 Altitude [m] Run Autotune The Autotune procedure can be run using the Quick Start procedure on the Overview page or it can be selected from the Motor Control page. Autotune provides an automatic method for determining various motor tuning attribute values, by measuring physical attributes of the motor that is connected to the Armor PowerFlex drive. By actually measuring these motor characteristics for the specific motor that is being used (instead of relying on default values, typical values for the motor type and size, or nominal values provided by a motor manufacturer), motor control performance is improved. The Autotune routine also uses the motor Name Plate Data values that are entered in the Motor Control page. It is important that you entered the Name Plate Data values for the motor, correctly. The drive can perform static and rotate Autotune operations. Perform these steps to run Autotune. 1. Click Autotune. You must be online with the programmable controller. If not, you will see the following offline message after clicking Autotune. Autotune Offline Error Message Rockwell Automation Publication 35-UM001G-EN-P - September 2024 173 Chapter 7 Configure the Armor PowerFlex Drive After clicking Autotune when online, the Autotune online request message is displayed. Autotune Online Message Example — Module Not Inhibited Run Autotune 2. Follow all the prompts to put the drive in a ready to run state. This example has a Safety Connection and EM Brake Control (The prompts listed are based on the Armor PowerFlex configuration in the Device Definition page, therefore, the prompts that you see might differ from the ones shown in this example). For this example: • Connection — Check Inhibit Module box (The drive must be inhibited.) • Click Reset Ownership (The drive will default to hardwired Safety which allows torque to be permitted, so the drive is in a ready run state.) • Install the STO bypass plug (see STO Bypass Operation on page 100) • EM Brake Control Mode — When the EM Braked is properly connected, select “Automatic Control” or “Automatic or Manual Control” (see Configure Electromechanical Brake on page 186). If the EM Brake is not connected, select “Disabled”. IMPORTANT If motor control performance is important when using Sensorless Vector or Velocity Vector control, the Autotune function should be performed. If the performance does not improve after the Autotune function is completed, contact the motor manufacturer for the optimal motor characteristic references and overwrite the values that are identified in the Autotune step. IMPORTANT Autotune cannot be performed when torque is disabled in an Armor PowerFlex safety drive (35S). Install the safety bypass jumper (hardwired STO mode), see Hardwired STO Operation on page 100, or enable torque via a separate safety controller (network STO mode), see Integrated Safe Torque Off Function on page 106. Autotune cannot be performed when a safety connection has been configured. ATTENTION: Rotation of the motor in an undesired direction can occur during this procedure. To guard against possible injury and/or equipment damage, we recommend disconnecting the motor from the load before you continue. 174 Rockwell Automation Publication 35-UM001G-EN-P - September 2024 Chapter 7 Configure the Armor PowerFlex Drive 3. Click Run Autotune. Autotune page 4. From the Autotune dialog box, choose an option. See Table 61. Different quantities are measured based on the Autotune option that is selected and based on the type of motor that is connected to the drive. Table 61 - Autotune Options Options 1 “Static Tune” Description A static Autotune operation performs measurements of physical attributes of the attached motor without causing movement of the motor. Some electrical energy is output to the motor, but it is not driven in a way to cause movement. The number of physical quantities that can be measured during a static tune are limited. For induction motors, the following are measured during a static Autotune: • Induction Motor Stator Resistance • Induction Motor Rotor Resistance 2 “Rotate Tune” Use this Autotune operation when no motor movement is allowed or when the motor cannot be uncoupled from the load. A rotate Autotune operation performs measurements of physical attributes of the attached motor while the motor is moved. Moving the motor allows more physical quantities to be made and in some cases, more accurate measurements can be made. For induction motors, the following are measured during a rotate Autotune: • Induction Motor Stator Resistance • Induction Motor Rotor Resistance • Induction Motor Flux Current • Induction Motor Total Leakage Inductance • Induction Motor Mutual Inductance Use this Autotune operation when motor movement is allowed and the load can be uncoupled from the motor. The LOAD MUST BE DISCONNECTED / UNCOUPLED or the measurements will not be accurate. IMPORTANT For Velocity Vector Control (VVC), the recommended tune method is Rotate tune and not Static tune. A warning message is displayed if Static tune is used, because the precision of motor control will be diminished. Rockwell Automation Publication 35-UM001G-EN-P - September 2024 175 Chapter 7 Configure the Armor PowerFlex Drive ATTENTION: Autotune cannot be performed when a safety connection has been configured. ATTENTION: Rotation of the motor in an undesired direction can occur during this procedure. To guard against possible injury and/or equipment damage, we recommend disconnecting the motor from the load before you continue. 5. When the autotune procedure is done, you can choose to enter tuning values manually, accept test results, or acknowledge default values. 6. To use the measured quantities, click Accept Test Results. 7. Click Finish, when complete. The Autotune process requires that the Armor PowerFlex connection is inhibited. Once the Autotune process is completed and you have exited the Autotune window, you must uninhibit the connection. 8. See Standard Connection Settings on page 188 to uninhibit the connection. If Autotune was run from the Quick Start application, continue with Configure Motor Control on page 166. Configure Flying Start Enabling Flying Start lets the drive reconnect to a spinning motor at actual RPM. For details, see Flying Start on page 22. • Choose to enable or disable Flying Start by checking or unchecking the check box, respectively. ATTENTION: When flying start is enabled and the motor is starting from zero speed, the motor shaft can turn forward or reverse while the algorithm attempts to detect current speed. Configure Auto Restart The auto restart feature provides the ability for the drive to automatically perform a fault reset followed by a start attempt without any user intervention. 1. From the Motor Control menu, check the Enable Auto Restart check box. If Auto Restart is enabled, it can be configured to perform multiple fault clear/start attempt cycles in response to a single start request. 2. Choose the number of Auto Restart Tries (up to 9), which sets the maximum number of times the drive attempts to reset a fault and restart. IMPORTANT 176 The Auto Restart feature only clears a limited number of the following motor control related faults. Any other faults will not be cleared and the drive will not restart. The drive will also not restart after multiple simultaneous faults of any type occur. • Inverter - Ground Fault (event code 0x04250002) • Motor Thermal Overload - Overload, Hard (event code 0x04320001) • Temperature Sensor - Overtemperature, Hard (event code 0x04230002) Rockwell Automation Publication 35-UM001G-EN-P - September 2024 Chapter 7 Configure the Armor PowerFlex Drive 3. Choose an Auto Restart Delay time (up to 120 s), which defines the time between restart attempts if Auto Restart Tries is set to a value greater than zero. ATTENTION: Equipment damage and/or personal injury can result if this function is used in an inappropriate application. Do not use this function without review of applicable local, national, and international codes, standards, regulations, or industry guidelines. Configure Encoder Feedback The default setting for Encoder Feedback is Disable Encoder Feedback, which is selected when no encoder is used. When an encoder is being used in the system configuration, you must adjust the Encoder Feedback parameters for the type of encoder that is used. To achieve speed range/accuracy for SVC and VVC closed loop control, a minimum of 1024 PPR encoder is recommended. The encoder pulse is approximately 250 kHz. See Table 62 for encoder specifications. Table 62 - Encoder Specifications Type Supply Quadrature Phasing Duty Cycle Requirements Incremental User-selectable 5V or 12V, 250 mA 90 ± 27° @ 25° C (77° F) 50%, +10% Encoders must be line driver type, quadrature (dual channel) or pulse (single channel) output, single-ended or differential and capable of supplying a minimum of 10 mA per channel. Allowable input is DC up to a maximum frequency of 250 kHz. The encoder inputs automatically scale to allow 5V, 12V DC nominal input signal voltages. Rockwell Automation Publication 35-UM001G-EN-P - September 2024 177 Chapter 7 Configure the Armor PowerFlex Drive 1. If you are using an encoder, click Encoder Feedback. 2. Choose the Electrical Interface Type: • Digital Incremental, Single Channel, Single Ended • Digital Incremental, Single Channel, Differential • Digital Incremental, Dual Channel, Single Ended • Digital Incremental, Dual Channel, Differential • Generic Sine/Cosine 3. From the Encoder Feedback page, select the encoder parameters. See Table 63 on page 178. Table 63 - Encoder Feedback Parameters Configure Velocity Control Attribute Range Polarity Normal/Inverted Cycle Resolution 1…20,000 cycles/rev Cycle Interpolation 4 (default) Effective Resolution 1…80,000 cycles/rev Enable Velocity Comparison Diagnostic Enable/disable Description Choose between Normal (default) or Inverted as appropriate for your application. This is based on encoder rotation and evaluation requirements. This setting is used in the Effective Resolution calculation. The actual motor encoder cycle resolution. This is the raw encoder cycle resolution of the motor or encoder device type. This is used in the Effective Resolution calculation. The safety primary-feedback interpolated counts as oppose to the motion axis-feedback interpolated counts. For the Integrated Safety Functions module, this value is 4 and cannot be changed. This calculated value is the product of cycle resolution and cycle interpolation for the primary safety function evaluation. When enabled, this diagnostic compares the velocity that is determined by the encoder and the predicted or estimated velocity based on the motor control model. If the difference is too large, a Feedback Velocity Comparison Failure fault occurs. Velocity control refers to controlling of the speed of a connected motor. A speed is commanded by the user, and the motor control algorithms determine the output to the motor necessary to achieve this speed. Additionally, the motor control method and optional feedback device determine how accurately the commanded speed can be met (closed loop control versus open loop control). The Velocity Control settings include: setting the velocity limits, enabling or disabling the dynamic acceleration control, entering up to four preset values for velocities, acceleration times, deceleration times, and s-curves, and setting the minimum and maximum output frequencies. 178 Rockwell Automation Publication 35-UM001G-EN-P - September 2024 Chapter 7 Configure the Armor PowerFlex Drive Follow these steps to configure the Velocity Control settings. 1. Click Velocity Control. Velocity Limits 2. Enter the Minimum Velocity and Maximum Velocity (limits). See Table 64. Table 64 - Velocity Limits Attribute Minimum Velocity Range 0…400 Rev/s Maximum Velocity 0…400 Rev/s Description Sets the minimum velocity for the drive. Sets the maximum velocity for the drive. IMPORTANT Stop the drive before changing this setting. Rockwell Automation Publication 35-UM001G-EN-P - September 2024 179 Chapter 7 Configure the Armor PowerFlex Drive Preset Velocity, Acceleration Time, Deceleration Time, S-Curve Enter a value for each attribute on a preset row: Velocity, Acceleration Time, Deceleration Time, and S-Curve. Enter up to four total presets. 3. The Preset Velocity to be used, is selected using the output tags devicename.0.VelocityRefSelect_x (where x can be 0, 1, or 2). Table 65 and Table 66 show the bit definitions to select the Preset Velocities, Acceleration Times, Deceleration Times, and S-curves. Table 65 - Preset Velocity Output Tag Bit Configuration VelocityRefSelect_2 VelocityRefSelect_1 VelocityRefSelect_0 Preset Velocity to be used User velocity reference in output tag 0 0 0 (CommandedVelocity) 0 0 1 Preset 1 0 1 0 Preset 2 0 1 1 Preset 3 1 0 0 Preset 4 IMPORTANT If an illegal value is entered (a value that is not defined in the table) for the Velocity Output Tag, the CommandVelocity output tag is used. Table 66 - Preset Acceleration/Deceleration/S-Curve Output Tag Bit Configuration AccelRefSelect_2 AccelRefSelect_1 AccelRefSelect_0 0 0 0 0 1 0 0 1 1 0 0 1 0 1 0 IMPORTANT 180 Preset Acceleration Time, Deceleration Time, S-Curve to be used Preset 1 Preset 1 Preset 2 Preset 3 Preset 4 If an illegal value (a value that is not defined in the table) is entered for the Preset Acceleration/Deceleration/S-Curve Output Tag, Preset 1 is used. Rockwell Automation Publication 35-UM001G-EN-P - September 2024 Chapter 7 Configure the Armor PowerFlex Drive You can change Acceleration Time, Deceleration Time, and S-curve in real time by using a Message Instruction or datalink (for details, see Configure Datalinks on page 159). Output Datalinks required for dynamic acceleration control (see Datalinks Output for Dynamic Acceleration Control): • Acceleration/Deceleration Control Switch - If 0, acceleration presets are used. You select which preset defined on Velocity Control is used, by setting bits AccelRefSelect_0...2. - If 1, then you enter the required values in the custom controller tags added to the end of devicename.O structure in the Controller Tag tree, in the Logix Designer application. • Dynamic Acceleration Time Reference [s] • Dynamic Deceleration Time Reference [s] • Dynamic S-Curve Reference [%] Datalinks Output for Dynamic Acceleration Control Optionally, you can go to the Datalinks Input tab and add input datalinks that can be used as feedback (values are actually used by the drive) (see Datalinks Input for Dynamic Acceleration Control): • Actual Acceleration Time Reference used by drive [s] • Actual Deceleration Time Reference used by drive [s] • Actual S-Curve Reference used by drive [%] Datalinks Input for Dynamic Acceleration Control Rockwell Automation Publication 35-UM001G-EN-P - September 2024 181 Chapter 7 Configure the Armor PowerFlex Drive Attribute Velocity Acceleration Time Deceleration Time S Curve Description Sets the target velocity. Sets the rate of acceleration for all speed increases except during a jog function. See Figure 87 for a graphic example. Sets the rate of deceleration for all speed decreases except during a jog function. See Figure 87 for a graphic example. Sets the percentage of acceleration or deceleration time that is applied to ramp as an S curve. Half of the time is added at the beginning and half at the end of the ramp. See Figure 88 for a graphic example. Figure 87 - Ramp Acceleration and Deceleration [Maximum Velocity] rati o n ele De c 0 n [Minimum Velocity] 0 o rati Acc ele Speed [Accel Time x] Time [Decel Time x] Figure 88 - S-Curve Examples 100% S-Curve Target vel 50% S-Curve Target vel Target vel/2 S-Curve Time = Accel Time S-Curve Time Total Time to Accelerate = Accel Time + S-Curve Time Total Time to Accelerate = Accel Time + S-Curve Time Output Frequency 4. Enter your minimum and maximum Output Frequency settings. The values are actual frequency in Hz, not 100X the value. Jog Configuration 5. Enter values for reference speed, acceleration time, and deceleration time. These values are used for the jogging function when using the control tag, the Jog button on the drive, or the Direction Test in the Quick Start. 182 Rockwell Automation Publication 35-UM001G-EN-P - September 2024 Chapter 7 Configure Stop Control Configure the Armor PowerFlex Drive The Stop Control page includes attributes related to the stop control of the motor. 1. Click Stop Control. 2. Choose a Stop Mode from the pull-down menu. See Table 67. Your choice of Stop Mode can be also applied to different events, see Configure Events on page 191. Table 67 - Motor Stop Modes Modes Coast Ramp (default) DC Brake IMPORTANT Description When a stop is initiated, power to the motor is immediately removed resulting in an uncontrolled stop. When a stop is initiated, power to the motor is not interrupted, but the velocity is reduced to zero at a rate defined by the Deceleration Time. Power to the motor is not removed until zero velocity is achieved. This is a controlled stop. When a stop is initiated, power to the motor is not interrupted, but a user configured amount of DC current is injected into the motor to produce a more rapid stop. After either a fixed period or when the velocity reaches zero, power to the motor is removed. When Stop Mode is set to Coast, the EM Brake will not disengage if the EM Brake configuration is set to Auto or Auto-Manual. If you want to control the EM Brake with a stop mode of Coast, the EM Brake must be set to Manual. 3. Enable or disable the Bus Regulator function. The Bus Regulator reduces the Decel Rate as required to help prevent the DC Bus Voltage from increasing to the trip limit. ATTENTION: The bus regulator function is useful to help prevent nuisance overvoltage faults that result from aggressive decelerations, overhauling loads, and eccentric loads. However, it can also cause either of the following two conditions to occur. • Fast positive changes in input voltage or imbalanced input voltages can cause uncommanded positive speed changes • Actual deceleration times can be longer than commanded deceleration times — (However, a Stall Fault is generated if the drive remains in this state for 1 minute. If this condition is unacceptable, Bus Regulator must be disabled. In addition, installing a properly sized dynamic brake resistor provides equal or better performance in most cases.) Rockwell Automation Publication 35-UM001G-EN-P - September 2024 183 Chapter 7 Configure the Armor PowerFlex Drive 4. Enable or disable the Flux Brake function. The flux brake only applies to certain motor types, such as AC induction. Flux Braking causes over fluxing of the motor which reduces the motor speed faster than just the decel ramp alone. This feature is not intended for high inertia loads because over fluxing can cause excessive heat in the motor. Very long decel times can create heat. Configure DC Brake DC Brake attributes need to be adjusted when DC Brake is set for the Stop Mode or when the stop mode is Ramp to stop and DC Brake Injection is desired to hold the load in place for certain period of time after a ramped stop. Attribute Range DC Brake Level 0…30.6(1) A DC Brake Time 0…99.9 s Description This setting defines the maximum DC brake current, in Amps, applied to the motor when Stop Mode is set to Ramp to Stop or DC Brake Stop. See Figure 89 on page 184. This setting specifies the length of time that DC brake current is injected into the motor. See Figure 89 on page 184. (1) The maximum range value will vary based on the Drive Rating that is selected in the Device Definition. Default values are drive rating dependent and listed in the Armor PowerFlex AC Drives CIP Objects and Attributes Reference Data, publication 35-RD001. Figure 89 - DC Brake Example DC Injection Braking Mode Ramp-to-Stop Mode ge [DC Brake Time] ed } [DC Brake Time] Speed } ta Volts Speed Vo l Spe } Volts Speed Voltage [DC Brake Level] [DC Brake Level] Time Time Stop Command } Stop Command ATTENTION: If a hazard of injury due to movement of equipment or material exists, a mechanical braking device must be used. This feature must not be used with synchronous or permanent magnet motors. Motors can be demagnetized during braking. ATTENTION: Excess motor current and/or applied duration, could cause motor damage. Motor voltage can exist long after the Stop command is issued. The right combination of DC Brake Level and DC Brake Time must be determined to provide the safest, most efficient stop. 184 Rockwell Automation Publication 35-UM001G-EN-P - September 2024 Chapter 7 Configure the Armor PowerFlex Drive Configure Dynamic Brake IMPORTANT Stop the drive before changing this setting. Choose a Resistor option that matches the physical Dynamic Brake connected to the Armor PowerFlex. When the External Light Duty or External Normal duty options are selected, the dynamic brake feature is enabled. Then, set the DC Bus Threshold Voltage. IMPORTANT Frame size A drives (1…3 Hp) support the dynamic brake function. Do not use any type of brake resistor with frame size B drives (5…10 Hp) with firmware revision 2.001. You must update the firmware to revision 2.002 or higher, to enable an enhanced level of dynamic brake resistor protection. Value Not Specified Description Not used; no dynamic brake 3% duty cycle, for details see Light Duty Dynamic Brake Resistor Dynamic Brake External Light Duty Operation on page 185 Resistor External Normal Duty 5% duty cycle, for details see Standard Duty Dynamic Brake Resistor Operation on page 185 If the DC bus voltage falls below the value set in this parameter, the Dynamic Brake does not turn on. Lower values make the Dynamic Braking 77…850V DC function more responsive, but can result in nuisance Dynamic Brake activation. ATTENTION: Equipment damage can result if this parameter is set to a value that causes the dynamic braking resistor to dissipate excessive power. Parameter settings less than 770V DC should be carefully evaluated to confirm that the dynamic brake resistor’s wattage rating is not exceeded. In general, values less than 700V DC are not needed. Do not set the parameter above 810V DC because it will cause a DC Bus Overvoltage error. DC Bus Voltage Threshold Light Duty Dynamic Brake Resistor Operation When the light duty dynamic brake resistor is applied, the braking operation applies 100% duty cycle up to 10 seconds, followed by 3% duty cycle. Equivalent to Standard Duty Dynamic Brake Resistor Operation When the standard duty dynamic brake resistor is applied, the braking operation applies 100% duty cycle up to 60 seconds, followed by 5% duty cycle. Equivalent to Rockwell Automation Publication 35-UM001G-EN-P - September 2024 185 Chapter 7 Configure the Armor PowerFlex Drive Configure Electromechanical Brake To configure the control setting of the Electromechanical brake (EMB or EM brake), choose a Control Mode for the EM brake from the pull-down menu. If choosing Automatic Control or Automatic or Manual Control, also set the Off Delay and On Delay, see Figure 90. Control Mode Disabled Automatic Control (default)(1) Automatic or Manual Control(1) (2) Description The integrated EM brake contactor does not energize. Therefore, if the Armor PowerFlex drive is connected to a motor with an EM brake, it never releases. The EM brake releases automatically, once the drive starts and the Brake Off Delay timer is satisfied. It engages automatically once the drive stops and the Brake On Delay timer is satisfied (see Figure 90). When the delay is set to 0, the brake releases once a valid start is detected by the drive and engages once a valid stop condition has been detected. If Source Brake Release Mode is set to Automatic, then the Stop Mode must be set to Ramp. EM brake operation is based on the settings of output tag bits devicename:O.EMBrakeAutoManCtrl and devicename.O.EMBrakeRelease. The following table explains the bit settings and the EM brake state. For application examples, see Automatic or Manual Application Examples. Device Output Tag Bit EM Brake State EMBrakeAutoManCtrl EMBrakeRelease Manual Control Mode Automatic Control Mode Automatic or Manual Control Mode 1 1 Released Released 1 0 Engaged Engaged — when the motor Engaged control is stopped 0 1 Engaged Engaged — when the motor control is Released — when the motor stopped control is started Released — when the motor control is 0 0 Engaged started Ensure that devicename:O.EMBrakeRelease is in the correct state BEFORE the devicename:O.EMBrakeAutoManCtrl IMPORTANT transitions from 0 to 1. A brake status bit is accessible for diagnostic purposes over the network. You control if the EM brake is released or engaged based on the state of output bit devicename.O:manualEMBrakeRelease. ATTENTION: The Armor PowerFlex drive has no control over the EM brake in Controller Tag configuration. In Controller Tag mode, the programmable controller will control the EM brake. Precautions are required to ensure the EM brake is in the correct state at all times Controller Tag Control Off Delay(3) 0.00 - 10.00 s On Delay(3) 0.00 - 10.00 s Sets the time after a start command, that the drive remains at the minimum frequency before releasing/energizing the brake and ramping up to the commanded frequency (if EM Brake Control Mode is enabled). Sets the time at the end of a stop that the drive remains at the minimum frequency, after engaging/de-energizing the brake (if the EM Brake Control Mode is enabled). (1) This is an invalid configuration when Stop Mode is set to “Coast to Stop”. Change to “Controller Tag Control” for manual EM Brake control to command the EM Brake state. (2) Requires drive firmware revision 2.000 or higher. (3) The Off-Delay and On-Delay use the same timer. If the On-Delay timer setting is longer than Off-Delay timer setting and the On-Delay timer is interrupted before it reaches 0.0 seconds, a subsequent change in the RUN command can result. This RUN command change can occur in less than the programmed delay setting or in no delay time. We recommend to allow the delay timer to reach 0.0 seconds before initiating the opposite RUN command (1 -> 0 or 0->1). IMPORTANT 186 Cycling the Logix Designer configuration from Automatic to Manual to Automatic, the bit state must be in a known state BEFORE a subsequent change to Manual. Rockwell Automation Publication 35-UM001G-EN-P - September 2024 Chapter 7 Configure the Armor PowerFlex Drive Figure 90 - EM Brake Delay Timer Example Frequency EM Brk On Delay pA cce l Ram pD ece l R am EM Brk Off Delay Minimum Freq Start Commanded EM Brk Energized (Off) Time Stop Commanded EM Brk De-Energized (On) Drive Stops Automatic or Manual Application Examples Example 1 • EM Brake Mode: Automatic or Manual • EMBrakeAutoManCtrl = 0 [mode = automatic which is under drive control] • Drive Run commanded 0 to 1 • EMBrakeRelease = 0 (brake engaged by default), the motor starts and the brake is disengaged automatically because of the mode setting • Then, EMBrakeAutoManCtrl bit changes from 0 to 1 (Manual), motor still moves • EMBrakeRelease bit changes from 0 to 1 [brake disengaged] brake engaged but drive is still running. The brake will cause excess current to generate which will like cause a fault which is logged on Faults & Alarms page. Example 2 • EM Brake Mode: Automatic or Manual • EMBrakeAutoManCtrl = 1 [mode = manual] • Drive Run commanded 0 to 1 • EMBrakeRelease = 0 (default), the motor starts but the brake is still engaged • The brake will cause excess current to generate which will like cause a fault which is logged on Faults & Alarms page Click OK to exit the Stop Control page. Rockwell Automation Publication 35-UM001G-EN-P - September 2024 187 Chapter 7 Configure the Armor PowerFlex Drive Configure Connections Perform the steps in the following sections to configure your standard and safety output and input connections. Standard Connection Settings For standard connections, the drive uses unicast connections. With unicast, data is sent to one network device. For more information on unicast connections, see the Ethernet Reference Manual, publication ENET-RM002. 1. To open the Connection page, click Connection in the Module Properties window of the Armor PowerFlex drive. 2. Enter a value for the RPI rate for the Standard Connection. RPI Rate Default Setting Range 20.0 ms 2…3200 ms Description The RPI defines the slowest rate at which the drive produces input data to and consumes output data from the controller. 3. To Inhibit the connection check the check-box and click on the Apply or OK button. To Un-Inhibit the connection, uncheck the check-box and click on the Apply or OK button. The Inhibit Module check-box is unchecked by default. The Inhibit Module check-box allows you to indefinitely suspend a connection, including Listen Only connections, between an owner-controller and a digital I/O module without removing the module from the configuration. This process lets you temporarily disable a module, to perform maintenance. IMPORTANT You cannot inhibit a connection when the drive is safety-locked or a safety signature exists for the drive. This means that you cannot use the QuickStart procedure for editing the Armor PowerFlex drive. 4. Configure whether a drive connection failure, while the programmable controller is in Run mode, causes a major fault in the controller. Minor fault is the default. The Module Fault area of the Connection page provides a fault description and error code for troubleshooting. The connection between the owner and the Armor PowerFlex drive is based on the following: - Armor PowerFlex drive safety network number (when there is a safety connection) - Controller slot number - GuardLogix safety controller safety network number (when there is a safety connection) - Path from the controller to the Armor PowerFlex drive - Armor PowerFlex drive configuration signature If any differences are detected, the connection between the GuardLogix safety controller and the Armor PowerFlex drive is lost, and the yellow yield icon appears in the controller project tree after you download the program. 188 Rockwell Automation Publication 35-UM001G-EN-P - September 2024 Chapter 7 Configure the Armor PowerFlex Drive Safety Input and Output Connection Settings (safety variants only) Safety I/O connections are unicast only. On the connections page, follow these steps: 1. The RPI (Requested Packet Interval) for the Safety Input connection can be adjusted for the application. See the following table for additional information. The RPI for the Safety Output connection is a fixed value based on the period set for the safety task in the controller. RPI Rate Default Setting Range 10.0 ms 3…500 ms Description The RPI defines the slowest rate at which a module sends its data to the owner-controller. The time is sent to the module with all other configuration parameters. When the specified time frame elapses, the module sends data. 2. The Reaction Time Limit for the Safety Input and the Safety Output can be adjusted for the application. Click Edit to open the Connection Reaction Time Limit configuration window. 3. Enter values for the Timeout Multiplier and Network Delay Multiplier for both the Safety Output and Safety Input. These values are combined in a formula with the RPI, to calculate the Connection Reaction Time Limit. When you select appropriate RPIs, the system has maximum performance. Default Setting Range Timeout Multiplier 2 1…4 Network Delay Multiplier 200% 10…600% IMPORTANT Description To determine what is appropriate, analyze each safety channel. The default Timeout Multiplier of 2 and Network Delay Multiplier of 200 creates a worst-case input connection-reaction time limit of 4 times the RPI, and an output connection-reaction time limit of 3 times the RPI. The Connection Reaction Time Limit sets the maximum age of safety packets on the associated connection. If the age of the data that is used by the consuming device exceeds the connection reaction time limit, a connection fault occurs. Changes to these settings must be approved only after a thorough review by a safety administrator. 4. After the values are entered, click OK. A connection status tag, called ConnectionFaulted, exists for every connection. If the RPI and connection reaction time limit for the network are set appropriately, then this status tag must always remain low. Monitor all connection status bits to verify that they are not going high intermittently due to timeouts. This could be caused by a network issue and could be used as an Ethernet troubleshooting diagnostic. For more information about the Connection Reaction Time Limit, see the user manual for your safety controller. Rockwell Automation Publication 35-UM001G-EN-P - September 2024 189 Chapter 7 Configure the Armor PowerFlex Drive Configure Standard I/O Points Follow these steps to configure the standard I/O points. 1. From the Configuration menu, choose Input/Output Configuration. 2. Assign the Input Delay Time, OffOn (0…65,535 ms). The default value is zero. Delay time is for Off to On transition. Input must be high after input delay has elapsed before it is set logic 1. This delay time is configured per channel with each channel tuned to match the characteristics of the field device, for maximum performance. 3. Assign the Input Delay Time, OnOff (0…65,535 ms). The default value is zero. Delay time is On to Off transition. Input must be low after input delay has elapsed before it is set logic 0. This delay time is configured per channel with each channel tuned to match the characteristics of the field device, for maximum performance. If using the configurable I/O points as inputs, define an OffOn and OnOff delay time as described previously in step 2 and step 3. If using the configurable I/O points as outputs, you can configure the action that the output should take when one of the following conditions is detected. See Table 68. • Idle Action - Idle Network Connection to the Armor PowerFlex drive • Fault Action - Fault Network Connection to the Armor PowerFlex drive • Product Fault Action - Armor PowerFlex Fault • Power Loss Action - Armor PowerFlex loss of 3-phase power Table 68 - Configuration Actions and Availability Configuration Availability per Condition Idle Connection Product Power Loss Connection Fault Fault Configuration Actions Description On The output will turn On when the condition is detected and will stay On while the condition is present The output will turn Off when the condition is detected and will stay Off while the condition is present The output will hold the state at which it was when the condition was detected and will maintain this state while the condition is present This selection is for future use. It currently behaves as an Off configuration action. A fault occurs when the condition is detected The output will follow the command of the controller tag when a Power Loss is detected Off Hold Invalidate Fault Controller Tag 4. Click OK to close the Connection page. 190 Rockwell Automation Publication 35-UM001G-EN-P - September 2024 x x x x x x x x x x x x x x x x Chapter 7 IMPORTANT Configure the Armor PowerFlex Drive To operate properly, standard outputs require a minimum load of 10 mA, otherwise an over/under current error will occur. Configure Events Events configuration allows you to choose a result for a specific event. Your available events to configure will vary, depending on which firmware revision is selected, see Configure the Device Definition on page 156. Events Name — Firmware Revision 1 Output Phase Loss Brake Undercurrent, Hard Name — Firmware Revision 2 Discrete Output Overcurrent Detected Output Phase Loss Load Monitor, Above Level (Shear Pin)(1) (1) Brake Undercurrent, Hard Load Monitor, Below Level (Load Loss) Load Monitor, Above Level (Shear Pin)(1) Underspeed, Hard(2) Load Monitor, Below Level (Load Loss)(1) Overspeed, Hard(2) State Discrepancy(2) (1) Configuration options are not available in the AOP application revisions 1.03.xx and below. (2) This event applies to the fan. Choose from the available Type selections in Table 69, to configure each event. Table 69 - Event Type Configuration Type Fault Alarm - start inhibit Alarm - inform Information Disabled Description Fault may cause immediate damage and always stops the motor. It must be cleared, otherwise the motor cannot be restarted. If the event type is set to Fault, then you must configure how the drive stops the motor. You can either specify a Stop Mode for each event (see Table 70) or use the same Stop Mode that is used when the drive receives a stop command from the controller (Active Stop Mode option, see Configure Stop Control on page 183). Alarm - start inhibit does not stop the motor. The condition that triggered the alarm must be resolved, otherwise the motor cannot be restarted. Alarm - inform does not stop the motor. It may cause long term damage if the alarm condition is not resolved. Information notifies you about state of the drive. Disables the event. There is no corresponding event that is visible on the Faults and Alarms page. If the event type is Fault, choose from the available Stop Mode selections in Table 70, to configure each stop mode. Table 70 - Motor Stop Configuration Stop Mode Coast Ramp DC Brake Activate Stop Mode Description The motor comes to rest on its own; it is not a controlled stop. Ramp stops the motor after specified time. DC Brake provides rapid motor stop by DC current injection. Active Stop Mode stops the motor using the mode specified on the Stop Control page. See Configure Stop Control on page 183. Stop mode is used only when event type is set to Fault. Otherwise the configuration is ignored by the drive. Rockwell Automation Publication 35-UM001G-EN-P - September 2024 191 Chapter 7 Configure the Armor PowerFlex Drive Configure Safety Functions (safety version) Safety configuration includes the following pages: • Safety Configuration • Safety Feedback — (only available with an encoder) • Scaling — (only available with an encoder) • Safe Torque Off (STO) • Safe Brake Control (SBC) • Safe Stop 1 (SS1) • Input Configuration • Output Configuration • Actions Safety Configuration Reset Ownership For information, see Reset Ownership on page 97. Configure Safety Feedback Configure feedback if you intend to use any drive-based or controller-based safety function that monitors motion. There are many different combinations of feedback for velocity control and safety that can be configured. Safety Feedback only appears when Single Feedback Monitoring is selected as the Safety Instance in the Device Definition. Follow these steps to configure the Primary Feedback. 1. Select the Safety Feedback page. 192 Rockwell Automation Publication 35-UM001G-EN-P - September 2024 Chapter 7 Configure the Armor PowerFlex Drive 2. Enter your Safety Feedback attributes. Attribute Description Electrical Interface Type Select your type of feedback device. Polarity Defines the direction of counting versus the direction of motion. • Normal means counts increase when motion is in the positive direction. • Inverted means that counts decrease when motion is in the positive direction. Voltage Monitor Selects monitoring of voltage that is supplied to power the feedback. Cycle Resolution Cycle Interpolation Effective Resolution Defines the number of Cycles per Unit. The unit is typically meters for linear devices and revolutions for rotary devices. Defines the number of position Counts per Cycle. Defines the number of position Counts per Unit. Velocity Average Time Specifies the time period over which to average Feedback Velocity. Select 0 to disable averaging. Maximum Speed Defines the maximum allowable speed. Exceeding this speed causes a fault. Select 0 to set no maximum speed. Standstill Speed Defines the speed below which motion is considered stopped. Feedback Velocity above standstill speed will set either Motion Negative or Motion Positive attributes to 1. Acceleration Average Time Specifies the time period over which to average Feedback Acceleration. Select 0 to disable averaging. Maximum Acceleration Defines the maximum allowable acceleration. Exceeding this acceleration causes a fault. Select 0 to set no maximum acceleration. Value Disabled Safety Feedback - not specified (default) Digital Incremental, Dual Channel, Differential (aka. Digital AqB) Generic Sine Cosine Hiperface Normal (default) Inverted Not Monitored (default) 4.75…5.25V 11.4…12.6V cycles/rev counts/cycle counts/rev 0 ms (default) 0…1000 ms 0 rev/s (default) # rev/s 0 rev/s (default) # rev/s 0 ms (default) 0…1000 ms 0 rev/s² (default) # rev/s² Configure Scaling The scaling page lets you configure the position and time to be used in terms of counts per position unit (defined by the user) in the safe monitoring functions. It defines “Actual Speed” and “Actual Position” that is used to match the velocity controller. Select Scaling and enter the safety scaling attributes per the following table. Attribute Effective Resolution Position Units Time Units Position Scaling Description The number of counts per motor revolution, which is determined by the Primary Feedback category. The position units for this safety application. Enter text for the name of your units. The evaluation of position per unit of time for a velocity evaluation. Choose between Seconds (default) and Minutes, as appropriate for your application. The conversion constant showing the counts per position units. This is the number of counts for one of your position units. Rockwell Automation Publication 35-UM001G-EN-P - September 2024 193 Chapter 7 Configure the Armor PowerFlex Drive Configure Safe Torque Off From the Safety menu, choose Safe Torque Off (STO). The STO function can be configured to delay when torque is disabled, by entering an STO Delay value. To see how STO Delay affects operation, see Safe Torque Off Delay and Safe Torque Off Operation on page 108. STO Active command becomes active if any of the following inputs to STO are asserted: • STO Output = 0 • Safety Connection is Loss and Connection Loss Action = STO • Safety Connection is Idle and Connection Idle Action = STO • Drive-based SS1 Function is Complete (= 1) • Safety Stop Fault = 1 • Critical Safety fault occurs STO Output is a tag in the safety output assembly of the Armor PowerFlex drive that is used to activate the STO function for the drive. When any source for STO is asserted, the STO Active bit becomes high to indicate that the STO function is operating. STO Delay follows this sequence of events. 1. STO becomes active and the STO delay timer begins. 2. The STO delay timer expires. 3. Torque producing power is removed from the inverter output. • If STO is activated by a Safety Stop fault or Critical Safety fault, torque is removed immediately without the STO delay. • If STO is reset by removing all inputs that cause the STO Active command to be true, torque is immediately permitted without delay. 194 Rockwell Automation Publication 35-UM001G-EN-P - September 2024 Chapter 7 Configure the Armor PowerFlex Drive Configure Safe Brake Control (SBC) From the Safety menu, choose Safe Brake Control (SBC). SBC is configured when Safe Brake Control functionality is desired in an application. The default mode for SBC is ‘Not Used’. If the SBC functionality is desired, setting the mode to ‘Used, Test Pulses’, or setting the mode to ‘Used, No Test Pulses’, will enable the SBC function. When configured for ‘Used, Test Pulses mode’, pulse testing of the physical brake outputs are performed. For more information on the drive-based SBC function, see Safe Brake Control Function on page 116. See Table 71 for descriptions of the SBC attributes. Table 71 - SBC Attributes Attribute Description Determines if an STO event engages the brake. If set to ‘Not Linked’, an STO event does not engage the brake. If set to ‘Linked’, the brake is engaged during an STO STO Activates SBC event based on the ‘STO to SBC Delay’ attribute. This attribute is only valid when the ‘Mode’ is set to one of the two ‘Used’ options. The delay of brake engagement in milliseconds. If the value is a positive number, the delay specifies the time between when STO is activated and the brake is engaged. If value is a negative number, the brake is engaged immediately after STO is STO to SBC Delay the activated, and the delay specifies the time between STO activation and when torque is actually disabled. This attribute is only valid when ‘STO Activates SBC’ is set to’ Linked’. IMPORTANT Safety Output is used for SBC control. To configure the SBC, the Safety Bipolar Outputs need to be set to Not Used in the Configure Safety Output. See Configure Safety Outputs on page 200. Rockwell Automation Publication 35-UM001G-EN-P - September 2024 195 Chapter 7 Configure the Armor PowerFlex Drive Configure Safe Stop 1 From the Safety menu choose Safe Stop 1 (SS1). SS1 is configured when a Timed or Monitored Safe Stop 1 condition is desired. ‘Timed SS1’ mode is available when the module is configured with or without safety feedback monitoring. The ‘Monitored SS1’ mode is only available when the module Safety Instance in the Device Definition is configured for single feedback monitoring (for more information on the drive-based Safe Stop 1 function, see Safe Stop 1 Function on page 111.) Timed SS1 is a fixed time for the motor to stop before removing torque. Motor feedback is not monitored. ‘Stop Delay’ is the only parameter that is used for ‘Timed SS1’ and determines the ‘Max Stop Time’. 196 Rockwell Automation Publication 35-UM001G-EN-P - September 2024 Chapter 7 Configure the Armor PowerFlex Drive Monitored SS1 is a ramped safe-stop where the motion safety instance monitors the speed ramp to standstill speed, while the drive controls the deceleration to standstill speed. When standstill is reached, the motion safety instance removes torque from the motor. Configure these settings: Property Mode Description Specifies the mode of the SS1 function. The Mode selection determines which attributes on the tab are available to configure. The available options are: • Not Used • Timed SS1 • Monitored SS1 Monitored SS1 is unavailable when the Safety Instance on the Device Definition window is set to ‘Safe Stop, Only’. Stop Monitor Delay Stop Delay Max Stop Time Decel Reference Speed Decel Reference Rate Decel Speed Tolerance Standstill Speed The delay time before deceleration is monitored. Valid values are 0...65535. This option is not available when ‘Mode’ is ‘Timed SS1’. The stop delay time used when the SS1 function is initiated by a stop type condition. Displays the SS1 maximum stop time. This value is the sum of ‘Stop Delay ‘and ‘Stop Monitor Delay’. Specifies the deceleration speed to monitor for SS1. This parameter is unavailable when ‘Mode’ is ‘Timed SS1’. The minimum rate of deceleration while stopping. Changing the Stop Delay value recalculates the Decel Reference Rate. This parameter is unavailable when ‘Mode’ is ‘Timed SS1’. The speed tolerance that is applied to the deceleration ramp check. The speed limit that is used to declare motion as stopped. Rockwell Automation Publication 35-UM001G-EN-P - September 2024 197 Chapter 7 Configure the Armor PowerFlex Drive Configure Test Outputs If you have configured safety inputs to use a test output, follow these steps to configure the test outputs: 1. From the Safety menu, choose Input Configuration. 2. In the Test Output dialog box, assign a point mode. See Table 72. IMPORTANT Only valid Test Output selections will be allowed based on your configured safety inputs. See Configure Safety Inputs. Table 72 - Test Output Configuration Point Mode Not Used Test Pulse Output Power Supply Output Description The test output is disabled. Used to test a safety input for short circuit detection. Test output is configured for power supply. For test output specifications, see Test Output Specifications on page 146. Configure Safety Inputs Follow these steps to configure the safety inputs. 1. In the Input Configuration dialog box, assign the Point Operation Type. See Table 73. - 198 Rockwell Automation Publication 35-UM001G-EN-P - September 2024 Chapter 7 Configure the Armor PowerFlex Drive Table 73 - Point Operation Types Type Single Channel Dual Channel Equivalent Dual Channel Complementary Description Inputs are treated as single channels. Dual-channel safety inputs can be configured as two individual single channels. This configuration does not affect pulse tests because it is handled on an individual channel basis. IMPORTANT: Use single-channel mode when you intend to use the GuardLogix safety application instructions. Inputs are treated as a dual-channel pair. The channels must match within the discrepancy time or an error is generated. Inputs are treated as a dual-channel pair. They must be in opposite states within the discrepancy time or an error is generated. 2. When you choose Dual Channel Equivalent or Dual Channel Complementary, you must also consider the Discrepancy Time. A Discrepancy Time of 0 ms disables the discrepancy check. The Discrepancy Time accepts values of 0…65535 in increments of 1 ms. IMPORTANT Configuring discrepancy time on Armor PowerFlex safety inputs masks input discrepancies that are detected by the controller safety instructions. The controller reads status to obtain this fault information. 3. Assign the Point Mode. See Table 74. Table 74 - Input Point Modes Point Mode Not Used Description The input is disabled. If 24V is applied to the input terminal, it remains logic 0. The input point is enabled and performs as a Standard Input. Used as Standard Input The associated Test Output can be used to provide 24V DC power supply but it has to be configured for Power Supply. The input point is enabled and performs a pulse test on the input. When the input is Used with Test Output energized, the input pulses low briefly. The pulse test detects whether the input is functioning properly. Verify that the associated Test Output is set to Pulse Test. Used without Test The input point is enabled and does not perform a pulse test on the input. Output 4. 5. 6. 7. When the input Point Mode is Used With Test Output: - Test Output 0 is associated with safety inputs 0 and 2. - Test Output 1 is associated with safety inputs 1 and 3. Assign the Input Delay Time, Off to On (0…65,535 ms, in increments of 1 ms). The default is 0 ms. Filter time is for Off to On transition. Input must be high after input delay has elapsed before it is set logic 1. This delay time is configured per channel with each channel tuned to match the characteristics of the field device, for maximum performance. Assign the Input Delay Time, On to Off (0…65,535 ms, in increments of 1 ms). The default is 0 ms. Filter time is On to Off transition. Input must be low after input delay has elapsed before it is set logic 0. This delay time is configured per channel with each channel tuned to match the characteristics of the field device, for maximum performance. From the Input Error Latch Time field, enter the time that the module holds an error to make sure that the controller can detect it (0…65,535 ms, in increments of 1 ms - default 1000 ms). This setting provides more accurate diagnostics. The purpose for latching input errors is to make sure that intermittent faults that can exist only for a few milliseconds are latched long enough for the controller to read. The amount of time to latch the errors are based on the RPI, the safety task watchdog, and other application-specific variables. Click Apply. Rockwell Automation Publication 35-UM001G-EN-P - September 2024 199 Chapter 7 Configure the Armor PowerFlex Drive Configure Safety Outputs The dual channel mode features bipolar safety outputs which must be configured the same. The Armor PowerFlex drive treats the outputs as a pair and sets them high (1) or low (0), as a matched pair. Output configuration is not available when Safe Brake Control (SBC) is enabled. Safety logic must set both of these outputs On or Off simultaneously or the module declares a channel fault. Follow these steps to configure the safety outputs. 1. From the Safety menu, choose Output Configuration. 2. Assign the Point Mode. See Table 75. Table 75 - Safety Output Point Mode Point Mode Not Used Used without Test Pulses Used with Test Pulses Description The output is disabled. The output point is enabled and does not perform a pulse test on the output. The output point is enabled and performs a pulse test on the output. When the output is energized, the output pulses low briefly. The pulse test detects whether the output is functioning properly. 3. Enter the Output Error Latch Time. Attribute Description Specifies the amount of time in milliseconds an Output error will be latched. If the error Output Error Latch Time is no longer present after this time, the error condition can be reset. Configure Safety Listen Only Connection The Armor PowerFlex drive supports an additional safety input, listen only connection, which allows for a separate safety controller to be configured to receive the safety input assembly data from the Armor PowerFlex drive. This can be used to receive safety status data to coordinate between safety systems. See Table on page 209 for information on mapping the listen only connection input data tags to the safety input data tags. IMPORTANT 200 The listen only connection requires that the safety device has initially been configured through the Armor PowerFlex Add on Profile configuration for a standard and safety or safety only connection. The configuring connection and listen only connection must be in separate controllers. Rockwell Automation Publication 35-UM001G-EN-P - September 2024 Chapter 7 Configure the Armor PowerFlex Drive Add Safety Listen Only Connection The safety listen only connection is configured through the Generic EtherNet/IP Safety page in Studio 5000. 1. In the New Module Menu, select the ETHERNET-SAFETYMODULE profile and click Create. 2. Enter the Name and Ethernet Address fields in the New Module creation page. The Ethernet Address should match the address of the desired Armor PowerFlex device that you want to receive safety status information from. 3. Enter the Safety Network Number (SNN). The SNN field needs to match the SNN set by the controller which owns the safety connection. You can determine this from the Armor PowerFlex Device Definition page. See Configure the Device Definition on page 156 for more information. The safety network number can also be determined by a get attribute single CIP message to class 0xF5, instance 1, attribute 7. 4. Click Change, under the Connection Parameter fields. Rockwell Automation Publication 35-UM001G-EN-P - September 2024 201 Chapter 7 Configure the Armor PowerFlex Drive 5. Configure the following values in the Module tab in the Module Definition page, as shown. 6. Click the Connection tab in the Module Definition page and configure the information as shown. 7. Click OK on the Module Definition page, then click OK on the New Module page, to finish creating the safety listen only connection profile. 202 Rockwell Automation Publication 35-UM001G-EN-P - September 2024 Chapter 7 Configure the Armor PowerFlex Drive Configure Safety Actions Use the settings on the Actions page to: • Define the action to take when the safety connection is lost. • Define the action to take when the safety connection goes idle. • Define the restart and cold start behavior. Restart is the restart behavior while operating. A cold start is the restart behavior when applying controller power or controller mode changes to ‘Run’. Follow these steps to configure the safety actions. 1. From the Safety Configuration menu, choose Actions . 2. Choose the safety action values. See Table 76. Click on icons for detailed instructions. Table 76 - Safety Action Value Descriptions Attribute Connection Loss Action Connection Idle Action Description Values Description • Connection loss is caused by removal of Safe Stop 1 Drive-based Safe Stop 1 function is initiated and operates according to the the Ethernet cable from the drive. (SS1) SS1 configuration. • The loss could also be an indication of excessive traffic, causing the drive to Safe lose synchronization to the grandmaster Torque Off Torque is removed according to the STO configuration. clock controller. (STO) Safe Stop 1 Connection idle is caused by the safety (SS1) output task becoming disabled because the controller goes from run to Remote Safe Program mode. Torque Off (STO) Drive-based Safe Stop 1 function is initiated and operates according to the SS1 configuration. Torque is removed according to the STO configuration. Restart automatically allowed after safety function completes and function Automatic request is removed. If restart is Defines whether the safety function should required due to a fault, a manual restart manually or automatically reset once the must be performed. Restart Type be function is complete and the function Restart is allowed after removing any request is removed. faults if present, disabling the safety Manual function request tag, and a 0->1 transition of SO.ResetRequest bit. Safety function is automatically ready Automatic for operation after the controller is Cold start type means that the configured switched to Run Mode. function is ready for operation Cold Start Type safety Safety function requires a manual reset immediately after the controller enters run after the contoller is switched to Run mode. Manual Mode. Restart is allowed after a 0->1 transition of SO.ResetRequest bit. Rockwell Automation Publication 35-UM001G-EN-P - September 2024 203 Chapter 7 Configure the Armor PowerFlex Drive Table 76 - Safety Action Value Descriptions Attribute STO Reaction Description Values Defines if the drive or if the controller Drive should perform the stopping action in response to an STO activation. If there is no standard network connection at the time of the STO activation, the drive will initiate the Controller stop. Coast Ramp which stop method should be used STO Stop Mode Defines for the motor for STO activation. DC Brake SS1 Reaction Defines if the drive or if the controller Drive should perform the stopping action in response to an SS1 activation. If there is no standard network connection at the time of the SS1 activation, the drive will initiate the Controller stop. Coast Ramp which stop method should be used SS1 Stop Mode Defines for the motor for SS1 activation. DC Brake 204 Rockwell Automation Publication 35-UM001G-EN-P - September 2024 Description The drive automatically reacts to the STO activation by performing a stop. The controller manages the reaction to the STO activation. When a stop is initiated, power to the motor is immediately removed resulting in an uncontrolled stop. When a stop is initiated, power to the motor is not interrupted, but the velocity is reduced to zero at a rate defined by the Deceleration Time. Power to the motor is not removed until zero velocity is achieved. This is a controlled stop. When a stop is initiated, power to the motor is not interrupted, but a user configured amount of DC current is injected into the motor to produce a more rapid stop. After either a fixed period or when the velocity reaches zero, power to the motor is removed. The drive automatically reacts to the SS1 activation by performing a stop. The controller manages the reaction to the SS1 activation. When a stop is initiated, power to the motor is immediately removed resulting in an uncontrolled stop. When a stop is initiated, power to the motor is not interrupted, but the velocity is reduced to zero at a rate defined by the Deceleration Time. Power to the motor is not removed until zero velocity is achieved. This is a controlled stop. When a stop is initiated, power to the motor is not interrupted, but a user configured amount of DC current is injected into the motor to produce a more rapid stop. After either a fixed period or when the velocity reaches zero, power to the motor is removed. Chapter 7 Using Automatic Device Configuration Configure the Armor PowerFlex Drive Automatic Device Configuration (ADC) supports the automatic download of drive configuration data. It is always active in the drive and cannot be disabled. Drive configuration settings are stored in the Logix controller. With ADC, the Logix controller automatically downloads the configuration settings for a particular drive each time the Logix controller connects to the Armor PowerFlex drive. ATTENTION: Logix holds the Master copy of the drive configuration. ADC is triggered any time the Armor PowerFlex drive detects a configuration signature mismatch when establishing an EtherNet/IP network I/O connection. No other configuration tools are supported. Any Armor PowerFlex drive configuration changes must be made by editing the Module Properties in the Logix Designer project. Auto-generated Tags After you configure the Armor PowerFlex drive, the drive tags are generated for standard and safety inputs and outputs. The data from the input (produced) and output (consumed) assemblies is used as descriptive tag names to simplify programming. To find the status of the configurable I/O, see Configurable I/O Operation on page 89. IMPORTANT Review the CONNECTION_STATUS Data section of the GuardLogix 5580 and Compact GuardLogix 5380 Controller Systems Safety Reference Manual, publication 1756-RM012, for information on how to use the connection status tags. Table 77 - Standard Input Tags Input Tag DeviceName.I.DriveStatus DeviceName.I.Ready DeviceName.I.Running DeviceName.I.CommandedDirection DeviceName.I.ActualDirection Function Bitmask of status bits below 0 = Motor control is not ready to run (see run inhibits for details) 1 = Motor control is ready to run, there is nothing blocking a run request 0 = Motor control is not running, no power output to motor 1 = Motor control is running, power is being output to the motor 0 = Current commanded direction is reverse 1 = Current commanded direction is forward Indicates the actual direction of motion when Running = 1, not valid if Running = 0 0 = Actual direction of motion is reverse 1 = Actual direction of motion is forward Rockwell Automation Publication 35-UM001G-EN-P - September 2024 205 Chapter 7 Configure the Armor PowerFlex Drive Table 77 - Standard Input Tags Input Tag DeviceName.I.Accelerating DeviceName.I.Decelerating DeviceName.I.AtReferenceSpeed DeviceName.I.Fault DeviceName.I.SafetyIn0Monitor DeviceName.I.SafetyIn1Monitor DeviceName.I.SafetyIn2Monitor DeviceName.I.SafetyIn3Monitor DeviceName.I.SafetyOutMonitor DeviceName.I.SafeTorqueEnabled DeviceName.I.SafetyFault DeviceName.I.In_0 DeviceName.I.In_1 DeviceName.I.In_2 DeviceName.I.In_3 DeviceName.I.IO_0 DeviceName.I.IO_1 DeviceName.I.KeypadButtonF0 DeviceName.I.KeypadButtonF1 DeviceName.I.KeypadButtonF2 DeviceName.I.KeypadHandMode DeviceName.I.ThreePhaseACPowerPresent DeviceName.I.DisconnectClosed DeviceName.I.EMBrakeReleased DeviceName.I.Alarm DeviceName.I.OutputFrequency DeviceName.I.OutputVoltage DeviceName.I.OutputCurrent DeviceName.I.OutputPower DeviceName.I.DCBusVoltage DeviceName.I.DriveHeatsinkTemperature DeviceName.I.EncoderCounts DeviceName.I.MotorOverloadLevel DeviceName.I.TripFaultCode DeviceName.I.CurrentVelocity 206 Function Set to 1 if motor control is accelerating (increasing velocity) to achieve velocity reference Set to 1 if motor control is decelerating (decreasing velocity) due to a stop or to achieve velocity reference Set to 1 if motor control is running and the current velocity is the velocity reference Set to 1 if there is an unacknowledged fault present Safety input 0 state, 0 = off, 1 = on (35S only) Safety input 1 state, 0 = off, 1 = on (35S only) Safety input 2 state, 0 = off, 1 = on (35S only) Safety input 3 state, 0 = off, 1 = on (35S only) Safety output 0 (bipolar output) state, 0 = off, 1 = on (35S only) Set to 1 if the safety logic is permitting torque (power output to motor), else 0 (35S only) Set to 1 if there is a safety specific fault present (35S only) Standard input 0 state, 0 = off, 1 = on Standard input 1 state, 0 = off, 1 = on Standard input 2 state, 0 = off, 1 = on Standard input 3 state, 0 = off, 1 = on Self-configuring I/O point 0 state when used as an input, 0 = off, 1 = on Self-configuring I/O point 1 state when used as an input, 0 = off, 1 = on State of front panel keypad button F0 (Local/Auto), 0 = not pressed, 1 = pressed State of front panel keypad button F1 (Forward/Reverse), 0 = not pressed, 1 = pressed State of front panel keypad button F2 (Jog), 0 = not pressed, 1 = pressed Set to 1 if the front panel keypad is in the local state (it is in control of the motor) Set to 1 if there is 3-phase AC power detected on the power input connector State of the AC power disconnect switch, 0 = open/off, 1 = closed/on Set to 1 if the EM brake is released (energized), else 0 Set to 1 if there is an active alarm condition present Frequency of the output to the motor, in hertz Voltage of the output to the motor, in volts, AC Current being output to the motor, in amps Power being output to the motor, in kilowatts Voltage of the internal DC bus, in volts, DC Temperature of the motor output heatsink, degrees Celsius Raw encoder (feedback device) counts Motor thermal overload level as a percentage (0% to 100%) Fault / event code of the first fault that caused the device to enter the faulted state, 0 if no unacknowledged faults present Current estimated or measured velocity of the motor, valid if Running = 1 Rockwell Automation Publication 35-UM001G-EN-P - September 2024 Chapter 7 Configure the Armor PowerFlex Drive Table 78 - Standard Output Tags Output Tag DeviceName.O.LogicCommand DeviceName.O.Stop DeviceName.O.Start DeviceName.O.Run DeviceName.O.Jog DeviceName.O.DirectionCmd_0 DeviceName.O.DirectionCmd_1 DeviceName.O.ClearFault DeviceName.O.AccelRefSelect_0 DeviceName.O.AccelRefSelect_1 DeviceName.O.AccelRefSelect_2 DeviceName.O.VelocityRefSelect_0 DeviceName.O.VelocityRefSelect_1 DeviceName.O.VelocityRefSelect_2 DeviceName.O.IO_0 DeviceName.O.IO_1 DeviceName.O.EMBrakeAutoManCtrl(1) DeviceName.O.EMBrakeRelease DeviceName.O.CommandedVelocity Function Bitmask of command bits below A 0 to 1 transition will cause motor control to perform a stop Motor control is blocked from running if set to 1 A 0 to 1 transition will cause motor control to attempt to run Motor control will attempt to run when set to 1, and remain running until set back to 0 Motor control will attempt to jog (run with preset speed) when set to 1, and remain jogging until set back to 0 0,0 or 1,1 = No direction commanded, current direction is maintained 1,0 = Forward direction commanded 0,1 = Reverse direction commanded A 0 to 1 transition will acknowledge or clear all active faults 0,0,0 = Use default acceleration reference (Acceleration Preset 1) For configuration, see Table 66 on page 180. 0,0,1 = Use Acceleration Preset 1 0,1,0 = Use Acceleration Preset 2 0,1,1 = Use Acceleration Preset 3 1,0,0 = Use Acceleration Preset 4 0,0,0 = Use velocity reference in output tag (CommandedVelocity) For configuration, see Table 65 on page 180. 1,0,0 = Use Velocity Preset 1 0,1,0 = Use Velocity Preset 2 1,1,0 = Use Velocity Preset 3 0,0,1 = Use Velocity Preset 4 Controls the state of the self-configuring I/O point 0 0 = output off / input mode, 1 = output on If using this I/O point as an input, this should remain 0 Controls the state of the self-configuring I/O point 1 0 = output off / input mode, 1 = output on If using this I/O point as an input, this should remain 0 Controls whether manual EM brake control via the DeviceName.O.EMBrakeRelease bit is enabled. 0 = Manual brake control is disabled, DeviceName.O.EMBrakeRelease bit ignored 1 = Manual brake control is enabled, DeviceName.O.EMBrakeRelease determines EM brake state in modes “Automatic or Manual Control” or “Manual Control” 1 = Manually release (energize) the EM brake (This tag member is ignored on units without EM brake control circuitry) Dynamic velocity reference value, used if DeviceName:O.VelocityRefSelect = 0,0,0 (1) Only available if firmware revision 2.000 or higher is selected and if you configure EM Brake to Automatic or Manual Control. Table 79 - Safety Input Tags Safety Input Tags DeviceName.SI.ConnectionStatus DeviceName.SI.RunMode DeviceName.SI.ConnectionFaulted DeviceName.SI.FeedbackPosition Function Bitmask of status bits below Safety Connection: 0 = Idle 1 = Run Safety Connection: 0 = Normal 1 = Faulted Indicates the actual position of the feedback device. Rockwell Automation Publication 35-UM001G-EN-P - September 2024 207 Chapter 7 Configure the Armor PowerFlex Drive Table 79 - Safety Input Tags Safety Input Tags DeviceName.SI.FeedbackVelocity DeviceName.SI.StopStatus DeviceName.SI.STOActive DeviceName.SI.SBCActive DeviceName.SI.SS1Active DeviceName.SI.SafetyFault DeviceName.SI.RestartRequired DeviceName.SI.SafeStatus DeviceName.SI.TorqueDisabled DeviceName.SI.BrakeEngaged DeviceName.SI.MotionStatus DeviceName.SI.MotionPositive DeviceName.SI.MotionNegative DeviceName.SI.FunctionSupport DeviceName.SI.PrimaryFeedbackValid DeviceName.SI.SBCReady DeviceName.SI.SS1Ready DeviceName.SI.OutputStatus DeviceName.SI.Out00Monitor DeviceName.SI.Out01Monitor DeviceName.SI.Out00Status DeviceName.SI.Out01Status DeviceName.SI.Test00Status DeviceName.SI.Test01Status DeviceName.SI.InputStatus DeviceName.SI.In00Data 208 Function Indicates the Feedback velocity, the actual velocity of the feedback device. A collection of the following bits. Safe Torque Off (STO) function status 0 = Permit Torque 1 = Disable Torque Safe Brake Control (SBC) function status 0 = Release Brake 1 = Engage Brake Safe Stop 1 (SS1) function status: 0 = Not Active 1 = Active 1 = Safe Stop Fault present 1 = Fault Reset or Stop Restart is required A collection of the following bits. 0 = Torque Permitted 1 = Torque Disabled Indicates the status of SBC function: 0 = Brake Released 1 = Brake Engaged Reserved for future use; always 0. Indicates positive motion: 0 = No Positive Motion 1 = Positive Motion Indicates negative motion: 0 = No Negative Motion 1 = Negative Motion Reserved for future use; always 0. Indicates that valid feedback is being produced by a connected feedback device: 0 = Feedback Invalid 1 = Feedback Valid Indicates whether SBC function is ready for operation: 0 = Not Ready 1 = Ready Indicates whether SS1 function is ready for operation: 0 = Not Ready 1 = Ready A collection of safety output status, safety output monitor values, and test output status Output Monitor Value of Safety Output 0 0 = OFF 1 = ON Output Monitor Value of Safety Output 1 0 = OFF 1 = ON Status of Safety Output 0 0 = Alarm 1 = OK Status of Safety Output 1 0 = Alarm 1 = OK Status of Test Output 0 0 = Alarm 1 = OK Status of Test Output 1 0 = Alarm 1 = OK A collection of safety input values and status for each safety input Value of Safety Input 0 0 = OFF 1 = ON Rockwell Automation Publication 35-UM001G-EN-P - September 2024 Chapter 7 Configure the Armor PowerFlex Drive Table 79 - Safety Input Tags Safety Input Tags DeviceName.SI.In01Data DeviceName.SI.In02Data DeviceName.SI.In03Data DeviceName.SI.In00Status DeviceName.SI.In01Status DeviceName.SI.In02Status DeviceName.SI.In03Status DeviceName.SI.IOSupport DeviceName.SI.In00Valid DeviceName.SI.In01Valid DeviceName.SI.In02Valid DeviceName.SI.In03Valid DeviceName.SI.Out00Ready DeviceName.SI.Out01Ready Function Value of Safety Input 1 0 = OFF 1 = ON Value of Safety Input 2 0 = OFF 1 = ON Value of Safety Input 3 0 = OFF 1 = ON Status of Safety Input 0 0 = Alarm 1 = OK Status of Safety Input 1 0 = Alarm 1 = OK Status of Safety Input 2 0 = Alarm 1 = OK Status of Safety Input 3 0 = Alarm 1 = OK A collection of bits describing safety IO functionality Safety Input 0 Valid 0 = Data invalid 1 = Data valid Safety Input 1 Valid 0 = Data invalid 1 = Data valid Safety Input 2 Valid 0 = Data invalid 1 = Data valid Safety Input 3 Valid 0 = Data invalid 1 = Data valid Safety Output 0 Ready 0 = Not Ready 1 = Ready Safety Output 1 Ready 0 = Not Ready 1 = Ready Table 80 - Safety Output Tags Safety Output Tags DeviceName.SO.PassThruDataA1 DeviceName.SO.PassThruDataB1 DeviceName.SO.PassThruStopStatus DeviceName.SO.SBCIntegrity DeviceName.SO.SBCActive DeviceName.SO.SBCBrakeEngaged Function 32-bit data container holding general-purpose safety data passed from the safety controller. 32-bit data container holding general-purpose safety data passed from the safety controller. See the following descriptions of Safe Stop Function Status bits. Status of an external Safety Brake controlled by SBC function. 0 = SBC fault. The brake status, released or engaged, is undetermined. 1 = No faults detected. Indicates that the SBC function is active and the sequence to set the Safety Brake has started. This function is only available as a controller-based function. 0 = SBC Function is not Active 1 = SBC Function is Active Indicates that the External Safety Brake is engaged by the controller-based SBC function. 0 = Brake is Engaged 1 = Brake is Released Rockwell Automation Publication 35-UM001G-EN-P - September 2024 209 Chapter 7 Configure the Armor PowerFlex Drive Table 80 - Safety Output Tags Safety Output Tags DeviceName.SO.SS1Active DeviceName.SO.SS2Active DeviceName.SO.SOSActive DeviceName.SO.SOSStandstill DeviceName.SO.PassThruSpeedLimitStatus1 DeviceName.SO.SSMActive DeviceName.SO.SSMStatus DeviceName.SO.SLSActive DeviceName.SO.SLSLimit DeviceName.SO.SDIActive DeviceName.SO.SDILimit DeviceName.SO.PassThruPositionLimitStatus DeviceName.SO.SCAActive DeviceName.SO.SCAStatus DeviceName.SO.SLPActive DeviceName.SO.SLPLimit DeviceName.SO.SFHomed DeviceName.SO.PassThruStopFaults DeviceName.SO.SFXFault DeviceName.SO.SBCFault DeviceName.SO.SS1Fault DeviceName.SO.SS2Fault DeviceName.SO.SOSFault 210 Function Indicates that the controller-based SS1 function is active. 0 = SS1 Function is not Active 1 = SS1 Function is Active Indicated that the controller-based SS2 function is active. 0 = SS2 Function is not Active 1 = SS2 Function is Active Indicates that the controller-based SOS function is active. 0 = SOS Function is not Active 1 = SOS Function is Active Indicates that the controller-based SOS function has detected Standstill according to the function configuration. 0 = Monitored axis is not at Standstill 1 = Monitored axis is at Standstill See the following descriptions of Limit Function Status bits. For use with a controller-based SSM function. For use with a controller-based SSM function. Indicates that the controller-based SLS function is active. 0 = SLS Function is not active 1 = SLS Function is active Indicates that the controller-based SLS function has detected the monitored axis speed above the limit setpoint. 0 = axis is below setpoint speed 1 = axis is greater than or equal to the setpoint speed Indicates that the controller-based SDI function is active. 0 = SDI Function is not active 1 = SDI Function is active Indicates that the controller-based SDI function detected motion greater than the limit in the unintended direction. 0 = Limit not reached 1 = Unintended motion See the following descriptions of individual bits, indicating the Monitoring Function Limit status of controller-based functions. For use with a controller-based SCA function. For use with a controller-based SCA function. Indicates that the controller-based SLP function is active. 0 = SLP Function is not active 1 = SLP Function is active Indicates that the controller-based SLP function has detected the monitored axis position outside of the setpoint limits. 0 = axis position is within the limits 1 = axis position is outside of the limits Status of the controller-based SFX position homing function. 1 = SFX Homed See the following descriptions of individual bits, indicating the Safety Fault status of controller-based safety functions. Indicates that a fault occurred with the controller-based SFX function. 0 = Normal Operation 1 = Fault Indicates that a fault occurred with the controller-based SBC function. 0 = Normal Operation 1 = Fault Indicates that a fault occurred with the controller-based SS1 function. 0 = Normal Operation 1 = Fault Indicates that a fault occurred with the controller-based SS2 function. 0 = Normal Operation 1 = Fault Not available, always 0. Rockwell Automation Publication 35-UM001G-EN-P - September 2024 Chapter 7 Configure the Armor PowerFlex Drive Table 80 - Safety Output Tags Safety Output Tags DeviceName.SO.PassThruLimitFaults DeviceName.SO.SLSFault DeviceName.SO.SDIFault DeviceName.SO.SLPFault DeviceName.SO.SafetyStopFunctions DeviceName.SO.STOOutput DeviceName.SO.SBCOutput DeviceName.SO.SS1Request DeviceName.SO.ResetRequest DeviceName.SO.SafetyIOCommands DeviceName.SO.Out00Output DeviceName.SO.Out01Output Function See the following descriptions of individual bits, indicating the Safety Fault status of controller-based safety functions. Controller-based SLS fault. 0 = Normal Operation 1 = Fault Controller-based SDI fault. 0 = Normal Operation 1 = Fault Controller-based SLP fault. 0 = Normal Operation 1 = Fault A collection of bits used to activate (request) safety functions as described in this table. Control Safe Torque Off (STO): 0 = Disable Torque 1 = Enable Torque If Safe Brake Control (SBC) is configured: 0 = Engage Brake (So0 and So1 OFF) 1 = Release Brake (So0 and So1 ON) If Safe Brake Control is not configured, this tag must be set to 0. If set to 1, will cause SBC fault. If Safe Stop 1 (SS1) is configured: 0 = No Request 1 = Request Safe Stop 1 If Safe Stop 1 is not configured, this tag must be set to 0. If set to 1, will cause SS1 fault. A 0 to 1 transition is required to reset Safety Faults. If Restart Type is ‘Manual’, a 0 to 1 transition is required to restart a Safety Stop Functions. See the following descriptions of individual bits. Command Safety Output 0 Command Safety Output 1 Table 81 - Safety Listen Only Tags Safety Listen Only Tags DeviceName.I.Data[0] DeviceName.I.Data[1] DeviceName.I.Data[2] DeviceName.I.Data[3] DeviceName.I.Data[4] DeviceName.I.Data[5] DeviceName.I.Data[6] DeviceName.I.Data[7] DeviceName.I.Data[8] DeviceName.I.Data[9] DeviceName.I.Data[10] DeviceName.I.Data[11] Safety Input Tags DeviceName.SI.StopStatus DeviceName.SI.SafeStatus DeviceName.SI.MotionStatus DeviceName.SI.FunctionSupport DeviceName.I.Data[12] DeviceName.SI.OutputStatus DeviceName.I.Data[13] DeviceName.SI.InputStatus DeviceName.I.Data[14] DeviceName.SI.IOSupport Function the actual position of the feedback DeviceName.SI.FeedbackPosition Indicates device. the Feedback velocity, the actual DeviceName.SI.FeedbackVelocity Indicates velocity of the feedback device. Rockwell Automation Publication 35-UM001G-EN-P - September 2024 A collection of the following bits. A collection of the following bits. Reserved for future use; always 0. Reserved for future use; always 0. A collection of safety output status, safety output monitor values, and test output status A collection of safety input values and status for each safety input A collection of bits describing safety IO functionality 211 Chapter 7 Configure the Armor PowerFlex Drive Notes: 212 Rockwell Automation Publication 35-UM001G-EN-P - September 2024 Chapter 8 Develop Secure Applications To enhance overall security, integrate your drive with these system components. FactoryTalk AssetCentre Server FactoryTalk® Directory Server Domain Controller FactoryTalk View SE Server Stratix® 5800 Switch Kinetix® 5700 Drive MOD NET MOD NET MOD NET 2 2 1 1 6 1 10 5 2 1 1 I/O MOD NET 2 2 1 1 MOD NET I/O-A 6 1 I/O-B 6 1 10 5 10 UFB-A UFB-B 5 1 I/O-A 6 1 I/O-B 6 1 10 5 10 UFB-A UFB-B 5 I/O-A 6 1 I/O-B 6 4 I/O 5 UFB D+ D- D+ D- MF-A D+ D- D+ D- MF-B MF-A 10 5 10 UFB-A UFB-B D+ D- D+ D- MF-B MF-A Armor™ PowerFlex® Drive Studio 5000 Logix Designer ControlFLASH Plus™ or ControlFLASH™ applications FactoryTalk View SE Client MF-B - MBRK + FactoryTalk® Security and FactoryTalk® Directory applications let you: • Manage user accounts and configure user groups to support the separation of duties and least privileged • Identify, authenticate, and authorize users • Configure strong password requirements FactoryTalk® AssetCentre application allows you: • Inventory assets • Configure and use auditable events • Manage audit storage capacity • Manage a diagnostics and health log • Manage change detection and reporting • Schedule backups • Recover from disruptions if they occur We recommend using a Windows® 10 operating system or higher, to achieve full software functionality. Rockwell Automation Publication 35-UM001G-EN-P - September 2024 213 Chapter 8 Develop Secure Applications For additional information to help you develop secure applications, reference these publications: Topic Publication Guidance on how to conduct security assessments, implement Rockwell Automation products in a secure system, harden the control system, manage user access, and System Security Design Guidelines Reference Manual, SECURE-RM001 dispose of equipment. Converged Plantwide Ethernet (CPwE) Design and Implementation Guide, publication Network architecture recommendations ENET-TD001 Windows® infrastructure recommendations (domain controller) How to configure and use these Rockwell Automation products: • FactoryTalk® Directory Security Configuration User Manual, publication SECURE-UM001. • FactoryTalk® Activation Manager • FactoryTalk® Security • FactoryTalk® AssetCentre How to configure and use CIP Security™ with Rockwell Automation products to CIP Security™ with Rockwell Automation Products Application Technique, publication improve the security of your industrial automation system, including the use of SECURE-AT001 FactoryTalk® Policy Manager to define communication between zones. CIP Security CIP Security is a standard, open-source communication mechanism that helps to provide a secure data transport across an EtherNet/IP network. CIP Security lets CIP-connected devices authenticate each other before transmitting and receiving data. CIP Security uses the following security properties to help devices protect themselves from malicious communication: • Device Identity and Authentication • Data Integrity and Authentication • Data Confidentiality Rockwell Automation uses the following products to implement CIP Security: • FactoryTalk® Policy Manager application (includes FactoryTalk System Services, version 6.20 or later) • FactoryTalk® Linx application, version 6.11 or later (lets workstation applications communicate securely using CIP Security) • Studio 5000 Logix Designer® application, version 32.00…34.xx and 36.xx or later This application is required to interface with CIP Security-enabled Logix controllers. The minimum application version varies by controller product family. For more information on CIP Security, for example, a list of CIP Security capable products and publications that describe how to use the products, including limitations and considerations, see the following: • Rockwell Automation - CIP Security • CIP Security with Rockwell Automation Products Application Technique, publication SECURE-AT001 Automatic Device Configuration Automatic Device Configuration supports control system backup and provides a means for the system to recover to a know secure state if a disruption occurs. See Using Automatic Device Configuration on page 205. The controller maintains a copy (backup) of the drive’s configuration data. Before establishing a controlling connection, the controller compares its copy of the product's configuration data to the product's actual configuration and updates the product's configuration data if they are different. Security configuration and network configuration settings are not included when using ADC. To use ADC: 214 Rockwell Automation Publication 35-UM001G-EN-P - September 2024 Chapter 8 Develop Secure Applications 1. Configure the drive’s IP address so that it can connect to your network. See Set the IP Address on page 69. 2. Make security configuration settings using FactoryTalk Policy Manager. 3. Connect to your controller to download configuration data. Syslog Event Logging The Armor PowerFlex drive supports syslog event logging for security-related events. Choose a syslog collector that supports the following: • RFC-5424 syslog protocol • Ability to receive messages from the drive To set the IP address of the syslog collector, use FactoryTalk Policy Manager software. For more information, see CIP Security with Rockwell Automation Products Application Technique, publication SECURE-AT001. Reset to Out-of-Box for Secure Erase A power-up with rotary address switches set to 888 triggers a factory reset to out-of-box configuration. A factory reset clears user-configurable settings such that the data cannot be retrieved with commercially available tools. It does not erase the following types of data: • Diagnostic data like, power on time • Security log data • Elapsed and remaining life data for components that are monitored for predictive maintenance Start is inhibited during a reset operation. For the reset procedure details, see Reset to Out-ofbox State on page 99. Disable Ethernet Ports Restrict the use of unnecessary ports, for example disable communication on network port 2 if only network port 1 is needed for application. IMPORTANT Remember the following: • Once a port is disabled, you lose any connection that is established through the controller Ethernet port. • You cannot disable Ethernet ports if the controller keyswitch is in Run mode or if the FactoryTalk Security settings deny this editing option. There are two ways to disable the Ethernet port: • Disable the Ethernet Port on the FactoryTalk Linx Configuration Tab on page 215 • Disable the Ethernet Port with a MSG Instruction on page 218 Disable the Ethernet Port on the FactoryTalk Linx Configuration Tab You can disable the Ethernet ports on the Armor PowerFlex drive using FactoryTalk Linx. IMPORTANT Once a port is disabled, it cannot be used with FactoryTalk Linx. So if both ports are disabled, FactoryTalk Linx will not be able to communicate with the unit. The Armor PowerFlex will have to be reset to factory default to enable communication again, see Reset to Out-of-box State on page 99. Rockwell Automation Publication 35-UM001G-EN-P - September 2024 215 Chapter 8 Develop Secure Applications Perform the following steps to disable a port of the Armor PowerFlex drive, using FactoryTalk Linx. 1. Launch the FactoryTalk Linx and create the appropriate EtherNet driver if needed. 2. Once you see the Armor PowerFlex IP Address listed under the EtherNet Driver, go to the advance settings as shown. 3. In Advanced Settings, check Enable Device Configuration under the General tab and click OK. This allows the IP Address to be changed using FactoryTalk Linx. 216 Rockwell Automation Publication 35-UM001G-EN-P - September 2024 Chapter 8 Develop Secure Applications 4. Right-click the device and choose Device Configuration. 5. Click on the Port Configuration tab. 6. Under the Enable column, uncheck the check box of the port that you want to disable. 7. Click Apply. 8. The port unchecked port is now disabled 9. To re-enable a port, repeat steps 1…7, but in step 6 check the check box of the port that you want to enable. Rockwell Automation Publication 35-UM001G-EN-P - September 2024 217 Chapter 8 Develop Secure Applications Disable the Ethernet Port with a MSG Instruction You can use a CIP Generic MSG to the drive, to disable one of the Ethernet ports. Follow these steps: 1. Add a MSG instruction to your program. This message only has to execute once, it does not need to execute with every program scan. IMPORTANT You cannot add a MSG instruction to your program if the controller keyswitch is in Run mode, or if the FactoryTalk Security settings deny this editing option. 2. In the Configuration tab, set the Message Type as CIP Generic. 3. Enter the remaining fields using the parameters in Table 82. Table 82 - Port Configuration Tab: MSG Parameter Service Code Class Attribute Value 0x10 0x00F6 1 2 9 Data Type USINT Instance IMPORTANT Description Set Attribute Single Motor Control Source EtherNet Port 1 EtherNet Port 2 Admin 0 = Reserve 1 = Enable Interface 2 = Disable Interface These values are stored to NVS memory in such a way that the MSG instruction is not required to execute each time the controller powers up. In this example, the controller tag is named Port_Configuration. - Source Length - 1 218 Rockwell Automation Publication 35-UM001G-EN-P - September 2024 Chapter 8 Develop Secure Applications 4. Configure the Communication tab to use a Path of THIS. (THIS is the name of the Armor PowerFlex drive used in the example.) IMPORTANT Messages to THIS must be unconnected messages. 5. Before you enable the MSG instruction, make sure that the Source Element tag value is 2. IMPORTANT You can re-enable an Ethernet port after it is disabled. To re-enable the port, complete the steps that are described in this section. Before you enable the MSG instructions, however, make sure that the Source Element tag value is 1. Rockwell Automation Publication 35-UM001G-EN-P - September 2024 219 Chapter 8 Develop Secure Applications Notes: 220 Rockwell Automation Publication 35-UM001G-EN-P - September 2024 Chapter 9 Diagnostics, Status, and Troubleshooting View Status Indicators The Armor PowerFlex drive has several groups of light-emitting diode (LED) status indicators, including system status, I/O status, EtherNet/IP status, power status, and keypad status, as described in this section. ATTENTION: Status indicators are not reliable for safety functions. Use status indicators only for general diagnostics during commissioning or troubleshooting. Do not attempt to use status indicators to determine operational status. System Status Indicator The system status LED (STATUS) indicates the overall state or status of the Armor PowerFlex drive. The STATUS LED operates the same for the Armor PowerFlex standard drive (35E) and the Armor PowerFlex safety drive (35S). See Table 83. Table 83 - STATUS LED State Drive is ready to run Drive is running LED Indicator Status Description Flashing green Drive is ready to run but is not running, no faults or alarms Steady green Drive is running, no faults or alarms Drive is not ready to run, motor control cannot be started OR Drive is not ready to run Flashing amber an alarm is present, device is not running Drive is running, alarm is present OR Drive is running with alarm Steady amber Drive is not ready to restart because a run inhibit condition is preventing a restart Fault is present, must be acknowledged by user before a Fault is present Flashing red motor control start can be accepted Major (nonrecoverable) Drive has a major non-recoverable fault, power cycle or Steady red fault is present replace unit Drive is in firmware update mode / firmware update in Firmware update mode Flashing green/red progress I/O Status Indicators The standard I/O LEDs consist of: • IN0: input • IN1: input • IN2: input • IN3: input • IN/OUT0: configurable I/O • IN/OUT1: configurable I/O Table 84 and Table 85 describe the I/O status indicator state and status. Table 84 - Standard Input LEDs: IN0…IN3 State Input off Input on Input fault LED Indicator Status Description Off Input is off, no fault Steady green Input is on, no fault Steady red Input is faulted Rockwell Automation Publication 35-UM001G-EN-P - September 2024 221 Chapter 9 Diagnostics, Status, and Troubleshooting Table 85 - Configurable I/O LEDs: IN/OUT0…IN/OUT1 State I/O off Input on Output on I/O fault LED Indicator Status Description Off Input or output is off, no fault Steady green Input is on, no fault Steady amber Output is on, no fault Steady red I/O point is faulted The safety I/O LEDs consist of: • SAFETY IN0: safety input • SAFETY IN1: safety input • SAFETY IN2: safety input • SAFETY IN3: safety input • SAFETY OUT0: safety output Table 86 and Table 87 describe the safety I/O status indicator state and status. ATTENTION: Do not use light-emitting diode (LED) status indicators on the safety I/O for safety operations. Do not use the colors as indication of safe or unsafe states. Table 86 - Safety Input LEDs: SAFETY IN0…SAFETY IN3 State Safety input off Safety input on Safety input fault Partner fault LED Indicator Status Description Off Input is off or not configured, no fault Steady green Input is on, no fault Steady red Input is faulted, due to wiring or input circuit fault Flashing red Partner input circuit of a dual-input configuration is faulted Table 87 - Safety Output LED: SAFETY OUT0 State Safety output off Safety output on Safety output fault LED Indicator Status Description Off Output is off or not configured, no fault Steady green Output is on, no fault Steady red Output is faulted, due to wiring or output circuit fault EtherNet/IP Status Indicators The EtherNet/IP LEDs consist of: • LINK A1: link activity • LINK A2: link activity • NET A: network status • MOD: EtherNet/IP module status Table 88, Table 89, and Table 90 describe the EtherNet/IP state and status. Table 88 - Ethernet Link Activity Status LEDs: LINK A1, LINK A2 State No link Link, no activity Link, with activity 222 LED Indicator Status Description Off No link Steady green Link is established, no activity Link, with activity - flash rate is dependent on level of traffic Flashing green on port, maximum flash rate of 100 ms on/100 ms off Rockwell Automation Publication 35-UM001G-EN-P - September 2024 Chapter 9 Diagnostics, Status, and Troubleshooting Table 89 - Ethernet Network Status LED: NET A State Not powered, no IP address Connected No connections Duplicate IP address Connection timeout Self test LED Indicator Status Description If the device does not have an IP address (or is powered Off), Off the network status indicator is steady Off. If the device has at least one established connection (even to Steady green the Message Router), the network status indicator is steady green. If the device has no established connections, but has Flashing green obtained an IP address, the network status indicator is flashing green. If the device has detected that the IP address is already in Steady red use, the network status indicator is steady red. If one or more of the connections in which this device is the target has timed out, the network status indicator is flashing Flashing red red. This indicator is turned Off only when all timeout connections are re-established or if the device is reset. While the device is performing its power-up test, the network Flashing red/green status indicator is flashing green/red. Table 90 - Ethernet Module Status LED: MOD State LED Indicator Status Description If no power is supplied to the device, the module status No power Off indicator is steady Off. If the device is operating correctly and the programmable Device operational Steady green controller is in Run mode, the module status indicator is steady green. If the device has not been configured or the programmable Standby Flashing green controller is not in Run mode, the module status indicator is flashing green. If the device has detected a nonrecoverable major fault, see Unrecoverable major fault Steady red Monitor Faults, Alarms, and Events. If the device has detected a recoverable major fault, the module status indicator is flashing red. Recoverable major fault Flashing red Note: An incorrect or inconsistent configuration is considered a minor fault. While the device is performing its power-up test, the module Self test Flashing red/green status indicator is flashing green/red. For Armor PowerFlex safety drive (35S), if there is no safety Waiting for TUNID or configuration and torque is not enabled via the hardwired Flashing red/green Configuring inputs, or the safety configuration process is occurring, the module status indicator is flashing red/green. Power Status Indicators The power status LEDs consist of: • LINE PWR: 3-phase AC power • SENSOR: indicates switched auxiliary/control 24V power (output power) - SENSOR refers to external power for items (sensors, output devices) connected to the product. This supply powers the user output circuits in the product. • CONTROL: indicates unswitched auxiliary 24V power (sensor power) - CONTROL refers to local power for the module itself. This supply powers the logic and user input circuits in the product. Table 91, Table 92, and Table 93 describe the power status indicator state and status. Rockwell Automation Publication 35-UM001G-EN-P - September 2024 223 Chapter 9 Diagnostics, Status, and Troubleshooting Table 91 - 3-phase Power LED: LINE PWR State 3-phase input power not present 3-phase input power present, drive On 3-phase input power present, drive Off LED Indicator Status Description 3-phase AC input power is not present, motor output is not Off possible. 3-phase AC input power is present, the local disconnect Steady green switch is On 3-phase AC power is present and the local disconnect switch Flashing green is Off Table 92 - SENSOR - Switched Auxiliary/Control 24V Power (Output Power) State Switched 24V power not present Switched 24V power present Switched 24V power present LED Indicator Status Description Switched 24V input power not present, user outputs on the Off drive are not operational Switched 24V input power is present and above the minimum Steady green required voltage Switched 24V input power is present but below the minimum Flashing red required voltage Table 93 - CONTROL - Unswitched Auxiliary/Control 24V Power (Sensor Power) State LED Indicator Status Description Unswitched 24V power not Off Unswitched 24V input power not present, drive is not present operational Unswitched 24V power Unswitched 24V input power is present and within operating Steady green present voltage range Unswitched 24V power Unswitched 24V input power is present but not within Flashing red present operating voltage range Keypad Status Indicators The keypad LEDs consist of: • LOCAL/AUTO MODE: The keypad LOCAL/ AUTO mode LEDs indicate if the Local/ Auto commands for the keypad buttons are active or not. • FUNCTION MODE: The keypad Function mode LED indicates whether the keypad is in Function mode. • LOCAL/AUTO: The keypad auto/local state LED indicates whether the keypad mode is auto mode, local mode, or another mode. • FWD/REV: The keypad forward/reverse LED indicates the selected direction of motion and whether there is motion when in the local keypad mode. • F0…F2: The keypad user function key LEDs (F0…F2) indicate that a keypad key is being pressed when the keypad mode is in user mode. Table 94, Table 95, Table 96, Table 97, and Table 98 describe the keypad status indicator state and status. Table 94 - LOCAL/AUTO MODE State LED Indicator Status Description LOCAL/AUTO keypad mode Off LOCAL/AUTO keypad mode is not available, keypad has been is not available configured for user mode LOCAL/AUTO keypad mode Steady green LOCAL/AUTO keypad mode is available is available Table 95 - LOCAL/AUTO State LED Indicator Status Description Keypad is in another mode Off Keypad is in Function mode or it has been disabled Keypad is in auto mode Steady green Keypad is in auto mode Keypad is in local mode Steady red Keypad is in local mode 224 Rockwell Automation Publication 35-UM001G-EN-P - September 2024 Chapter 9 Diagnostics, Status, and Troubleshooting An event named SourceActive (0X041C0009) will be logged whenever the Keypad is changed to Local mode. Table 96 - FWD/REV State Keypad mode is not local Keypad mode is local Keypad mode is local Keypad mode is local Keypad mode is local LED Indicator Status Description Off No Keypad control Keypad mode is local, direction that is selected is forward, no Steady green motion Keypad mode is local, direction that is selected is forward, Flashing green motion commanded (jogging, jog key pressed) Keypad mode is local, direction that is selected is reverse, no Steady red motion Keypad mode is local, direction that is selected is reverse, Flashing red motion commanded (jogging, jog key pressed) Table 97 - FUNCTION MODE State LED Indicator Status Description Keypad mode is something Off Keypad is in Local/Auto mode other than Function mode Unswitched 24V power Keypad has been configured for Function mode, local and Steady amber present auto modes are unavailable Table 98 - Function Keys F0…F2 State LED Indicator Status Description No key is being pressed OR Key is not being pressed in Function mode, or keypad mode is keypad is not in Function Off not user mode mode Key is pressed while in Steady amber Key is being pressed while in Function mode Function mode Safety Function Status Indicator The safety function LEDs consist of: • STO: Safe Torque Off • SAFETY FAULT: Table 99 - STO State Torque disabled Torque permitted Torque inhibited Circuit fault Nonrecoverable fault LED Indicator Status Description Torque is disabled (STO active = 1/Disable Torque). Off Device may not be powered, check Module Status LED The STO circuit is permitting torque Steady green (Torque Disabled = 0/Torque Permitted) Torque is enabled but the STO circuit is not permitting torque Flashing green (STO Active = 0/Permit Torque, Torque Disabled = 1/Torque Disabled) Flashing red The STO circuit is faulted Steady red A nonrecoverable fault has occurred Table 100 - SAFETY FLT State Normal operation Recoverable fault Nonrecoverable fault LED Indicator Status Description Steady green Normal operation Flashing red A recoverable fault has occurred Steady red A nonrecoverable fault has occurred Rockwell Automation Publication 35-UM001G-EN-P - September 2024 225 Chapter 9 Diagnostics, Status, and Troubleshooting Monitor Faults, Alarms, and Events The Armor PowerFlex drive provides notification of critical faults, major faults, major alarms, and events. ATTENTION: Do not attempt to defeat or override fault circuits. Determine the cause of the fault indication and correct it before an operation attempt. Failure to correct a control system or mechanical malfunction can result in personal injury and /or equipment damage due to uncontrolled machine system operation. • • • • When a critical fault occurs, all motor control operations stop. Motor power is immediately removed, which causes the attached motor to coast to a stop. A major fault stops the drive with a stop mode of coast. A major alarm notifies you of a condition that exists, but does not stop motor control operations, if the drive is already in a run condition. If the alarm occurs while the drive is in a stop condition, the alarm must be cleared for a run condition to be accepted. Alarms are cleared automatically when the condition that caused the alarm is no longer present for at least one second. An event occurs during normal operation of the product and can help you monitor status or troubleshoot problems. The Armor PowerFlex drive’s fault log, accessible from the Faults and Alarms page, displays the fault code, name of the fault, timestamp, and type of fault (Event, Alarm, Fault) and details about the fault. Faults and Alarms Page — Online Additional fault details are available for high severity faults. To access these details, click on the blue i logo that appears in the Details column. Fault Details Access 226 Rockwell Automation Publication 35-UM001G-EN-P - September 2024 Chapter 9 Diagnostics, Status, and Troubleshooting Fault Details Example Set Date and Time For an accurate fault timestamp, you must synchronize the drive’s Real Time Clock (RTC) with your workstation. Set the time and date in the Logix Designer application using the following steps. 1. Click Date and Time. 2. On the Date and Time page, click Set from Workstation. A confirmation message will appear that indicates the date and time have been synchronized with your workstation. Rockwell Automation Publication 35-UM001G-EN-P - September 2024 227 Chapter 9 Diagnostics, Status, and Troubleshooting Saving Fault History If you go offline and do not close the Logix Designer application, events are cached until the Logix Designer application, is closed or you go online again. Faults and Alarms Page — Offline The log stores the 100 most recent entries in nonvolatile memory. The Clear Faults button, clears unacknowledged faults. The Clear log button, clears the fault log data. The Reset Module button cycles power to the drive. See Clearing Faults, for details. 228 Rockwell Automation Publication 35-UM001G-EN-P - September 2024 Chapter 9 Diagnostics, Status, and Troubleshooting Exporting Faults Faults can be exported to a file while offline (cached data) or while online. Exporting Faults While Offline When exporting faults while online, you will also be prompted for a location of where to save the file. Exporting Faults While Online Rockwell Automation Publication 35-UM001G-EN-P - September 2024 229 Chapter 9 Diagnostics, Status, and Troubleshooting Access Fault, Alarm, and Event Codes This manual links to Armor PowerFlex AC Drive Fault Codes Reference Data, publication 35-RD002, for a list of fault codes; download the spreadsheets now for offline access. Clearing Faults There are two types of faults that can occur on the drive; standard and safety. They are indicated by the following status bar descriptions: • Drive State: Faulted (standard fault) • Drive State: Safety Faulted (safety fault) Standard Fault When a standard fault occurs, there are three ways to clear it, if the condition that is causing the fault has been resolved: 1. Use the DeviceName.O.ClearFault tag. A 0 to 1 transition will acknowledge or clear all active non-Safety faults. If the tag already has a value of 1 and then a non-safety fault occurs, the fault will not be cleared. The 0 to 1 transition is required to acknowledge or clear all active non-safety faults. Connection must not be inhibited for this command to work. See Chapter 7 for additional information. 2. Use the Fault Clear button on the drive’s keypad. See Chapter 4 for additional information. 3. Use the Clear Faults or Clear Log button in the Fault and Alarms page of the Logix Designer application. Pressing these buttons will acknowledge or clear all active nonsafety faults. The Clear Log button will also clear the fault memory. Connection must not be inhibited for this command to work. (Clearing all faults might require additional actions, such as cycling main input power). See Chapter 4 for additional information. Clear Log and Clear Faults Buttons 230 Rockwell Automation Publication 35-UM001G-EN-P - September 2024 Chapter 9 Diagnostics, Status, and Troubleshooting 4. The Reset Module button cycles power to the drive. It is not the typical method of clearing faults. For the typical method, using Clear Log and Clear Faults buttons, see step 3. To continue with the Reset Module button, you must be online and have selected Inhibit Module on the Connections page. For details, see Standard Connection Settings. IMPORTANT During Reset Module, the Logix Designer application is locked and you cannot perform any other actions until the reset is completed. Reset Module Rockwell Automation Publication 35-UM001G-EN-P - September 2024 231 Chapter 9 Diagnostics, Status, and Troubleshooting Safety Fault When a Safety Fault occurs, this is the sequence of steps to clear it (if the condition that created the fault has been resolved): 1. Make sure that there is a running connection between the programmable controller and Armor PowerFlex. The connection must not be inhibited. When the Armor PowerFlex connection is inhibited, controller tags are not exchanged between the programmable controller and the drive, therefore updates are not possible (e.g. this is similar to putting the programmable controller in Program Mode). 2. Use the DeviceName:SO.ResetRequest tag. A 0 to 1 transition will clear all active Safety faults. If the tag already has a value of 1 and then a Safety fault occurs, the fault will not be cleared. The 0 to 1 transition is required to clear all active Safety faults. See Chapter 6 for details on Safety Functions and Safety Faults. 232 Rockwell Automation Publication 35-UM001G-EN-P - September 2024 Chapter 9 Condition Monitoring Diagnostics, Status, and Troubleshooting The drive monitors the condition of the following physical components: • Power supply • Temperature When these components operate outside their limits, a fault or alarm can be triggered. See Armor PowerFlex AC Drives Fault Codes Reference Data, publication 35-RD002. You can use a message instruction to get status information about these physical components of the drive. See Armor PowerFlex AC Drives CIP Objects and Attributes Reference Data, publication 35-RD001 and the example in Power Supply on page 233. Power Supply The voltage of internal and external power supplies is monitored and a fault occurs if they are outside the valid range (20.4 …26.4V): • 0x04260001 Undervoltage, Hard • 0x04260002 Overvoltage, Hard You can use a message instruction to get the status of the internal or external power supplies (active or inactive), the nominal and measured voltage and more. For message instruction information, see Armor PowerFlex AC Drives CIP Objects and Attributes Reference Data, publication 35-RD001. You can also use a message instruction to get the state of the front panel disconnect switch (on/off) used to interrupt 3-phase AC power to the drive. Service Code Class Instance Data Type 0X0E 0X0426 4 BOOL Attribute 8 Get attribute single Power supply object 3-phase AC power (for motor) — Physical switch state o = The physical switch is in the off position. Power is not being supplied to the end device. 1 = The physical switch is in the on position. Power is being supplied to the end device. Temperature Sensor The drive monitors the temperature of system and power boards, the IGBT heatsink, and the system processor. A fault (0x04230002 Overtemperature, Hard) occurs if the measured temperature of any of these components exceeds the predefined, fixed level at which damage may occur. Rockwell Automation Publication 35-UM001G-EN-P - September 2024 233 Chapter 9 Diagnostics, Status, and Troubleshooting Fan For Frame B, the fan will turn OFF either instantly or when a pre-determined time or condition requires it. Fan Diagnostics include: 1. Alarm that fan has reached its useful life. a. The user can enable or disable this. The default is enabled. b. The user may decide to replace the fan or not c. The user may elect to reset the alarm and continue d. The product is not expected to detect if the fan was actually replaced. e. The act of resetting should be added to the event log 2. Alarm that fan is not operating within its design specification. a. The default is Disable b. When the alarm is enabled, and the condition improves it should automatically clear 3. Fault if the fan has stopped or is well below minimum RPM and must be replaced. a. Fault can be changed to an Alarm. Fan underspeed fault can be configured as an alarm to allow continued operation with reduced performance if the fan is not operational. b. When a fault occurs, the unit will stop. If the fan recovers before the fault is annunciated, then the drive will continue operation as normal and reset the timer and stop timing. A fan fault requires you to acknowledge the fault by pressing the clear button locally or remotely, to resume operation. Until you replace the fan or the fan returns to normal operation, there will be a persistent alarm. When the fan issue is corrected, then the alarm will turn off. {make a table of the temps} 234 Rockwell Automation Publication 35-UM001G-EN-P - September 2024 Chapter 10 Maintenance and Repair The Armor PowerFlex drive does not require regular maintenance. We recommend that you check that the heatsink has good airflow and that the fan is not obstructed. Also inspect quick connections as needed, to ensure connections remain tight where exposed to shock and vibration. IMPORTANT Predictive Maintenance The functional safety part of the product does not need any maintenance (apart from proof testing, if applicable). For the functional safety part of the product, no spare parts are available and no repair is possible or intended by the user. In case of permanent fault, the device has to be taken out of order and replaced by another one. By using the Predictive Maintenance Component object (class 0x0414), the drive tracks the usage of and calculates the estimated remaining life of these drive components: Instance 1 2 3 4 5 Drive Component IGBT DC bus capacitor Heatsink fan Disconnect switch EM brake The Predictive Maintenance page displays the Elapsed and predicted Remaining Life of the components, the consumed life as a percentage of the components total life, and indicates whether the component is currently operational. Predictive Maintenance Page Example After the Logix Designer application reads the Predictive Maintenance data, the data is cached. IMPORTANT The Total Life value might not equal the sum of the Elapsed Life and Remaining Life values because the predictive maintenance process also accounts for environmental or load conditions. Only the heatsink fan predictive maintenance data can be reset after replacement of a heatsink fan. Click the Reset button to reset the heatsink fan predictive maintenance data. Rockwell Automation Publication 35-UM001G-EN-P - September 2024 235 Chapter 10 Maintenance and Repair Remove Power Before Servicing the Armor PowerFlex Drive Be aware of the following precautions while servicing the Armor PowerFlex drive. Precautions ATTENTION: Before replacing a component in a safety system, see Safety I/O Wiring on page 147. ATTENTION: The service of energized industrial control equipment can be hazardous. Electrical shock, burns, or unintentional actuation of controlled industrial equipment can cause death or serious injury. For safety of maintenance personnel and others who can be exposed to electrical hazards associated with maintenance activities, follow the local safety-related work practices (for example, the NFPA 70E, Part II in the United States). Maintenance personnel must be trained in the safety practices, procedures, and requirements that pertain to their respective job assignments. ATTENTION: Only qualified personnel familiar with adjustable frequency AC drives and associated machinery must plan or implement the installation, startup, and subsequent maintenance of the system. Failure to comply can result in personal injury and/or equipment damage. ATTENTION: This drive contains electrostatic discharge (ESD) – sensitive parts and assemblies. Static control precautions are required during installation, test, service, or repair of this assembly. Component damage can result if ESD control procedures are not followed. If you are not familiar with static control procedures, see Guarding against Electrostatic Damage, publication 8000-4.5.2, or any other applicable ESD protection handbook. ATTENTION: The drive contains high-voltage capacitors. After removal of the main power supply, the capacitor discharge process can take 30 seconds to several minutes before a safe voltage is reached. Before working on the drive, or before servicing any device on the motor side, follow the procedure Test for Hazardous Voltage, starting on page 237, to verify that power is isolated and to verify that there are no hazardous voltages present. Use the test points under the power section door to confirm there are no hazardous AC line voltages (Test points: D1, D2, D3), and to confirm that the DC Bus capacitor bank voltage is at a safe level (Test points: DC+, DC-). After confirming no hazardous voltages are present at the test points under the power section door, open the power section cover to access the terminal block. Measure the input power on the L1, L2, and L3 of the exposed terminal block to verify that the power has been removed and that no hazardous voltage is present. Failure to verify that power is removed before working on the drive, or failure to verify that no hazardous voltages are present before working on the drive can result in personal injury or death. Darkened display light-emitting diode (LED) status indicators are not an indication that capacitors have discharged to safe voltage levels. ATTENTION: An incorrectly applied or installed drive can result in component damage or a reduction in product life. Wiring or application errors, such as undersized motor, incorrect or inadequate AC supply, or excessive ambient temperatures can result in malfunction of the system. ATTENTION: The Armor PowerFlex drive is meant to be disconnected and replaced, only after proper lockout/tagout procedures have been employed. See TechConnect Document ID QA67224, for information about Armor PowerFlex lockout/tagout. 236 Rockwell Automation Publication 35-UM001G-EN-P - September 2024 Chapter 10 Maintenance and Repair Test for Hazardous Voltage Before servicing the Armor PowerFlex drive or any device in the motor side (motor, motor cables, motor brake, and so on), you must follow these steps to remove power from the Armor PowerFlex, verify power is removed, and test for hazardous voltage: 1. Remove power from the drive by removing the three-phase power using the isolating device upstream (system circuit breaker, for example). After removal of the main power supply, the capacitor discharge process can take 30 seconds to several minutes before a safe voltage is reached. 2. Loosen the screws to remove the power section door to gain access to the voltage test points: D1, D2, D3, DC-, and DC+. Frame A Frame B 3. Measure the AC line voltage test points D1, D2, D3 (line-to-line and line-to-ground) to verify that main power has been disconnected. 4. Measure DC voltage across DC- and DC+ test points to verify that the DC bus has discharged to zero volts. D3 D1 DC+ D2 DC- Rockwell Automation Publication 35-UM001G-EN-P - September 2024 237 Chapter 10 Maintenance and Repair 5. After verifying that there are no hazardous voltages present on test points: D1, D2, D3, DC-, or DC+, loosen the screws and remove the internal power section cover. Frame A Frame B 6. To verify that power has been removed and hazardous voltage is no longer present, take measurements on the exposed terminal block. Measure input power on L1, L2, and L3 (line-to-line and line-to-ground). Terminal block Input Output Terminal ground Input Terminal R Terminal S Line 1 Line 2 Terminal T Line 3 Terminal R Line 1 Output Terminal S Terminal T Line 2 Line 3 7. You can now proceed with Fuse Replacement or other service to the device. 238 Rockwell Automation Publication 35-UM001G-EN-P - September 2024 Terminal ground Chapter 10 Fuse Replacement Maintenance and Repair The following fuses can be replaced on the Armor PowerFlex drive: • Three 3-phase input line fuses • Two EM brake fuses • One fuse for Switched +24V power and one fuse for Unswitched +24V power 3-phase AC Power and EM Brake Fuse Replacement Table 101 - 3-phase Input Power and EM Brake Fuse Specifications Specification Part No. Description Current Interrupting Capacity Voltage Rating Manufacturer Dimension mm (in.): 1. 3-phase AC Line Power Fuses Frame A Frame B KTK-20 LPJ-45SP 20 A, 600V AC, UL Listed 45 A, 600V AC, UL Listed Class CC, Std. 248-14 Class J, Std. 248-14 20 A 45 A 100 kA rms 100 kA rms 600V AC 600V AC Bussmann Bussmann 38.1 (1.5) x 10.3 (0.41) 60.4 (2.38) x 26.9 (1.06) EM Brake Fuses KTK-R-6 6 A, 600V AC, UL Listed Class CC, Std. 248-4 6A 200 kA rms 600V AC Bussmann 38.1 (1.5) x 10.3 (0.41) Loosen the screws and remove the power section door. See step 2 on page 237. 2. Loosen the screws and remove the internal power section cover. See step 5 on page 238. 3. Remove fuses from holding. We recommend using fuse puller FP-3 from Eaton/ Bussmann. When removing line power fuses, we recommend starting with the middle one, for ease of access. 4. Check each fuse with a multimeter to see if they are in good condition. If damaged, replace the fuses. Frame B Frame A Rockwell Automation Publication 35-UM001G-EN-P - September 2024 J J J 45 45 45 239 Chapter 10 Maintenance and Repair 5. Replace the internal power section cover. Tighten the screws. 1.37…1.57 N•m (12.1…13.9 lb•in). Frame A Frame B 6. Before replacing the power section door, re-apply power and measure DC voltage across DC- and DC+ test points to verify that the DC bus is re-energized. 7. Replace the power section door. Tighten the screws. 1.37…1.57 N•m (12.1…13.9 lb•in). Frame A 240 Rockwell Automation Publication 35-UM001G-EN-P - September 2024 Frame B Chapter 10 Maintenance and Repair Switched and Unswitched +24V DC Power Fuse Replacement Table 102 - 24V Fuse Specifications Specification Unswitched (Control) 24V DC Power Fuses Switched (Sensor) 24V DC Power Fuses Part No. 21502.5MXP 215004.MXP Description Fuse T C, 2.5 A, 250V, H CLIP Fuse T C, 4 A, 250V, H CLIP Current 2.5 A 4A Interrupting Capacity 1500 A @ 250V AC 1500 A @ 250V AC Voltage Rating 250V DC 250V DC Manufacturer Littlefuse Littlefuse Dimension mm (in.): 20 (0.78) x 5.2 (0.20) 21.5 (0.84) x 5.5 (0.21) 1. Loosen the screws and remove the logic section door screws. Frame A Frame B 2. Remove fuses from holding. We recommend using fuse puller FP-3 from Eaton/ Bussmann. Rockwell Automation Publication 35-UM001G-EN-P - September 2024 241 Chapter 10 Maintenance and Repair 3. Check each fuse with a multimeter to see if they are in good condition. If damaged, replace the fuses. FE BYPASS Unswitched 24V Fuse Switched 24V Fuse 4. Replace the logic section door. Tighten the screws. 1.37…1.57 N•m (12.1…13.9 lb•in). Frame A Frame B Fan Replacement For instructions on how to replace the fan, see the Armor PowerFlex Fan Replacement Kit Installation Instructions, publication 35-IN008. Bus Capacitor Maintenance For Armor PowerFlex units that are in storage and do not have voltage applied, maintenance of the capacitors maybe required. Follow these recommendations and guidelines for bus capacitor maintenance and reforming. Table 103 - Drive Storage Duration and Reforming Recommendations Duration <2 years 2…3 years >3 years 242 Reforming Guideline No reforming required. Apply rated voltage, per the normal method, for 30 minutes under no load. Contact your local sales representative to receive more specific engineering instructions. Rockwell Automation Publication 35-UM001G-EN-P - September 2024 Appendix A Integrated Safety Instruction Validation Checklist IMPORTANT The validation tests in this appendix only apply to these integrated safety functions: – Monitored Safe Stop 1 (SS1) – Safely Limited Speed (SLS) – Safely Limited Position (SLP) – Safe Direction (SDI) – Safety Feedback Interface (SFX) – Safe Brake Control (SBC) Use this appendix to validate your integrated safety instructions. Each instruction has a checklist with test commands and results to verify for normal operation and abnormal operation scenarios. For additional information on the safety instructions see the Drive Safety Chapter of GuardLogix Safety Application Instruction Set Reference Manual, publication 1756-RM095. Safe Stop 1 Use the Safe Stop 1 (SS1) instruction checklist in Table 104 to verify normal operation and the abnormal operation scenarios. IMPORTANT Perform I/O verification and validation before validating your safety ladder program. SFX instruction must be verified within your application. When possible, use immediate operands for instructions to reduce the possibility of systematic errors in your ladder program. Instruction operands must be verified for your safety ladder program. Table 104 - SS1 Instruction Checklist Test Type Normal Operation Test Description Initiate a Start command. • Verify that the machine is in a normal machine run condition • Verify proper machine status and safety application program status Operate the machine at the desired operating system speed. Set up a trend with expected time scale and the following tags to graphically capture this information: • SFX_Name.ActualSpeed • SS1_Name.SpeedLimit • SS1_Name.DecelerationRamp • SS1_Name.O1 Initiate SS1 demand. Make sure that the instruction output SS1_Name.01 turns off without generating a fault and that the drive initiates an STO instruction. • Verify that the STO instruction de-energizes the motor for a normal safe condition. While the system is stopped with the sensor subsystems in a safe state, initiate a Start command. • Verify that the STO instruction remains de-energized for a normal safe condition • Verify proper machine status and safety application program status While the system is stopped with the SS1 demand removed, initiate a Reset command of the STO and SS1 instructions. • Verify that the STO instruction remains de-energized • Verify proper machine status and safety application program status Rockwell Automation Publication 35-UM001G-EN-P - September 2024 Test Status 243 Appendix A Integrated Safety Instruction Validation Checklist Table 104 - SS1 Instruction Checklist (Continued) Test Type Abnormal Operation 1 Abnormal Operation 2 Test Description Change the actual motion deceleration rate within the motion task that is associated with this SS1 function so that it is slower than the calculated speed limit used by the SS1 instruction. Initiate a Start command. • Verify that the machine is in a normal machine run condition • Verify proper machine status and safety application program status Operate the machine at the desired operating system speed. Set up a trend with expected time scale and the following tags to graphically capture this information: • SFX_Name.ActualSpeed • SS1_Name.SpeedLimit • SS1_Name.DecelerationRamp • SS1_Name.O1 Initiate SS1 demand. Make sure that the instruction generates a deceleration fault and that the drive initiates an STO instruction. • Verify that the STO instruction de-energizes the motor for a normal safe condition While the system is stopped with the sensor subsystems in a safe state, initiate a Start command. • Verify that the STO instruction remains de-energized for a normal safe condition • Verify proper machine status and safety application program status While the system is stopped with the SS1 demand removed, initiate a Reset command of the STO and SS1 instructions. • Verify that the STO instruction remains de-energized • Verify proper machine status and safety application program status Change the motion deceleration rate within the motion task that is associated with this SS1 function so that the stop delay time is exceeded without triggering a deceleration fault. Initiate a Start command. • Verify that the machine is in a normal machine run condition • Verify proper machine status and safety application program status Operate machine at desired operating system speed. Set up a trend with expected time scale and the following tags to graphically capture this information: • SFX_Name.ActualSpeed • SS1_Name.SpeedLimit • SS1_Name.DecelerationRamp • SS1_Name.O1 Initiate SS1 demand. Make sure that the instruction generates a maximum time fault and that the drive initiates an STO instruction. • Verify that the STO instruction de-energizes the motor for a normal safe condition While the system is stopped with the sensor subsystems in a safe state, initiate a Start command. • Verify that the STO instruction remains de-energized for a normal safe condition • Verify proper machine status and safety application program status While the system is stopped with the SS1 demand removed, initiate a Reset command of the STO and SS1 instructions. • Verify that the STO instruction remains de-energized • Verify proper machine status and safety application program status Safely-limited Speed Use the Safety-limited Speed (SLS) instruction checklist in Table 105 to verify normal operation and the abnormal operation scenarios. IMPORTANT 244 Test Status Perform I/O verification and validation before validating your safety ladder program. SFX instruction must be verified within your application. When possible, use immediate operands for instructions to reduce the possibility of systematic errors in your ladder program. Instruction operands must be verified for your safety ladder program. Rockwell Automation Publication 35-UM001G-EN-P - September 2024 Appendix A Integrated Safety Instruction Validation Checklist Table 105 - SLS Instruction Checklist Test Type Normal Operation Abnormal Operation 1 Test Description Initiate a Start command. • Verify that the machine is in a normal machine run condition • Verify proper machine status and safety application program status Operate the machine within the desired speed range. Set up a trend with expected time scale and the following tags to graphically capture this information: SFX_Name.ActualSpeed SLS_Name.SLSLimit SLS_Name.ActiveLimit SLS_Name.Output 1 Initiate SLS demand. Verify that the drive achieves the speed below the SLS_Name.ActiveLimit without asserting the SLS_Name.SLSLimit output. While the system is in SLS monitoring state and with the sensor subsystems in a safe state, remove the SLS demand. • Verify proper machine status and safety application program status Resume normal machine operation. • Verify proper machine status and safety application program status Initiate a Start command. • Verify that the machine is in a normal machine run condition • Verify proper machine status and safety application program status Operate the machine within the normal speed range. Set up a trend with expected time scale and the following tags to graphically capture this information: SFX_Name.ActualSpeed SLS_Name.SLSLimit SLS_Name.ActiveLimit SLS_Name.Output 1 Initiate SLS demand. Verify that the drive achieves the speed below the SLS_Name.ActiveLimit without asserting the SLS_Name.SLSLimit output. While the system is in the SLS monitoring state, initiate a motion command that violates the SLS_Name.ActiveLimit. • Verify that the SLS_Name.SLSLimit output is asserted and the programmed stop action is initiated While the system is stopped with the sensor subsystems in a safe state, initiate a Start command. • Verify proper machine status and safety application program status While the system is stopped, initiate a Reset command. • Verify proper machine status and safety application program status Safely-limited Position Test Status Use the Safety-limited Position (SLP) instruction checklist in Table 106 to verify normal operation and the abnormal operation scenarios. IMPORTANT Perform I/O verification and validation before validating your safety ladder program. SFX instruction must be verified within your application. When possible, use immediate operands for instructions to reduce the possibility of systematic errors in your ladder program. Instruction operands must be verified for your safety ladder program. Rockwell Automation Publication 35-UM001G-EN-P - September 2024 245 Appendix A Integrated Safety Instruction Validation Checklist Table 106 - SLP Instruction Checklist Test Type Normal Operation Abnormal Operation 1 Abnormal Operation 2 246 Test Description Initiate a Start command. • Verify that the machine is in a normal machine run condition • Verify proper machine status and safety application program status Operate the machine within the desired position range. Set up a trend with expected time scale and the following tags to graphically capture this information: • SFX_Name.ActualPosition • SLP_Name.SLPLimit • SLP_Name.PositiveTravelLimit • SLP_Name.NegativeTravelLimit • SLP_Name.Output 1 Initiate SLP demand. Verify that the drive achieves and maintains a position between the SLP_Name.PositiveTravelLimit and the SLP_Name.NegativeTravelLimit without asserting the SLP_Name.SLPLimit output. While the system is in SLP monitoring state and with the sensor subsystems in a safe state, remove the SLP demand. • Verify proper machine status and safety application program status Resume normal machine operation. • Verify proper machine status and safety application program status Initiate a Start command. • Verify that the machine is in a normal machine run condition • Verify proper machine status and safety application program status Operate the machine within the desired position range. Set up a trend with expected time scale and the following tags to graphically capture this information: • SFX_Name.ActualPosition • SLP_Name.SLPLimit • SLP_Name.PositiveTravelLimit • SLP_Name.NegativeTravelLimit • SLP_Name.Output 1 Initiate SLP demand. Verify that the drive achieves and maintains a position between the SLP_Name.PositiveTravelLimit and the SLP_Name.NegativeTravelLimit without asserting the SLP_Name.SLPLimit output. While the system is in the SLP monitoring state, initiate a motion command that violates the SLP_Name.PositiveTravelLimit. • Verify that SLP_Name.SLPLimit output is asserted and the programmed stop action is initiated While the system is stopped with the sensor subsystems in a safe state, initiate a Start command. • Verify proper machine status and safety application program status While the system is stopped, initiate a Reset command. • Verify proper machine status and safety application program status Initiate a Start command. • Verify that the machine is in a normal machine run condition • Verify proper machine status and safety application program status Operate the machine within the desired position range. Set up a trend with expected time scale and the following tags to graphically capture this information: • SFX_Name.ActualPosition • SLP_Name.SLPLimit • SLP_Name.PositiveTravelLimit • SLP_Name.NegativeTravelLimit • SLP_Name.Output 1 Initiate SLP demand. Verify that the drive achieves and maintains a position between the SLP_Name.PositiveTravelLimit and the SLP_Name.NegativeTravelLimit without asserting the SLP_Name.SLPLimit output. While the system is in the SLP monitoring state, initiate a motion command that violates the SLP_Name.NegativeTravelLimit. • Verify that SLP_Name.SLPLimit output is asserted and the programmed stop action is initiated While the system is stopped with the sensor subsystems in a safe state, initiate a Start command. • Verify proper machine status and safety application program status While the system is stopped, initiate a Reset command. • Verify proper machine status and safety application program status Rockwell Automation Publication 35-UM001G-EN-P - September 2024 Test Status Appendix A Safe Direction Integrated Safety Instruction Validation Checklist Use the Safe Direction (SDI) instruction checklist in Table 107 to verify normal operation and the abnormal operation scenarios. IMPORTANT Perform I/O verification and validation before validating your safety ladder program. SFX instruction must be verified within your application. When possible, use immediate operands for instructions to reduce the possibility of systematic errors in your ladder program. Instruction operands must be verified for your safety ladder program. Table 107 - SDI Instruction Checklist Test Type Normal Operation Abnormal Operation 1 Test Description Initiate a Start command. • Verify that the machine is in a normal machine run condition • Verify proper machine status and safety application program status Operate the machine within the desired operating range. Set up a trend with expected time scale and the following tags to graphically capture this information: • SFX_Name.ActualPosition • SDI_Name.SDILimit • SDI_Name.PositionWindow • SDI_Name.Output 1 Initiate SDI demand. Verify that motion is in the intended direction and the SDI_Name.SDILimit output is not asserted. While the system is in SDI monitoring state and with the sensor subsystems in a safe state, remove the SDI demand. • Verify proper machine status and safety application program status Resume normal machine operation. • Verify proper machine status and safety application program status Initiate a Start command. • Verify that the machine is in a normal machine run condition • Verify proper machine status and safety application program status Operate the machine within the desired operating range. Set up a trend with expected time scale and the following tags to graphically capture this information: • SFX_Name.ActualPosition • SDI_Name.SDILimit • SDI_Name.PositionWindow • SDI_Name.Output 1 Initiate SDI demand. Verify that motion is in the intended direction and the SDI_Name.SDILimit output is not asserted. While the system is in the SDI monitoring state, initiate a motion command that violates the SDI_Name.PositionWindow in the unintended direction. • Verify that SDI_Name.SDILimit output is asserted and the programmed stop action is initiated While the system is stopped with the sensor subsystems in a safe state, initiate a Start command. • Verify proper machine status and safety application program status While the system is stopped, initiate a Reset command. • Verify proper machine status and safety application program status Safe Feedback Interface Test Status Use the Safe Feedback Interface (SFX) instruction checklist in Table 108 to verify normal operation and the abnormal operation scenarios. IMPORTANT Perform I/O verification and validation before validating your safety ladder program. SFX instruction must be verified within your application. When possible, use immediate operands for instructions to reduce the possibility of systematic errors in your ladder program. Instruction operands must be verified for your safety ladder program. Rockwell Automation Publication 35-UM001G-EN-P - September 2024 247 Appendix A Integrated Safety Instruction Validation Checklist Table 108 - SFX Instruction Checklist Test Type Normal Scaling Operation Normal Homing Operation Abnormal Operation 1 Abnormal Operation 2 248 Test Description Initiate a Start command. • Verify that the machine is in a normal machine run condition • Verify proper machine status and safety application program status Operate the machine within the normal operating range. Set up a trend with the expected time scale and the following tags to graphically compare the motion position and speed from the Main task to the scaled position and speed in the Safety task. • Axis_Name.ActualPosition • Axis_Name.ActualSpeed • SFX_Name.ActualPosition • SFX_Name.ActualSpeed Verify that the standard and safety position and speed are correlated as expected. Initiate a Start command. Initiate a Homing procedure. • Verify that the Home Position in the SFX instruction is set Set up a trend with the expected time scale and the following tags to graphically compare the motion position and speed from the Main task to the scaled position and speed in the Safety task. • Axis_Name.ActualPosition • SFX_Name.ActualPosition Verify that the standard and safety position are correlated as expected. Initiate a Start command. • Verify that the machine is in a normal machine run condition • Verify proper machine status and safety application program status Operate the machine within the normal operating range. Set up a trend with the expected time scale and the following tags to graphically compare the motion position and speed from the Main task to the scaled position and speed in the Safety task. • Axis_Name.ActualPosition • Axis_Name.ActualSpeed • SFX_Name.ActualPosition • SFX_Name.ActualSpeed Verify that the standard and safety position and speed are correlated as expected. Disconnect the feedback between the motor/encoder and drive. Verify the generation of a Fault Type: 100 Feedback Invalid by checking Device_Name.SI.PrimaryFeedbackValid tag. Verify that the system fault action takes place as configured. While the system is stopped with the sensor subsystems in a safe state, initiate a Start command. • Verify proper machine status and safety application program status While the system is stopped, initiate a Reset command. • Verify proper machine status and safety application program status Initiate a Start command. • Verify that the machine is in a normal machine run condition • Verify proper machine status and safety application program status Operate the machine within the normal operating range. Set up a trend with the expected time scale and the following tags to graphically compare the motion position and speed from the Main task to the scaled position and speed in the Safety task. • Axis_Name.ActualPosition • Axis_Name.ActualSpeed • SFX_Name.ActualPosition • SFX_Name.ActualSpeed Verify that the standard and safety position and speed are correlated as expected. Disconnect the Ethernet cable between the controller and the drive. Verify the generation of a Fault Type: 101 Connection Fault by checking the Device_Name.SI.ConnectionFaulted tag. Verify that the system fault action takes place as configured While the system is stopped with the sensor subsystems in a safe state, initiate a Start command. • Verify proper machine status and safety application program status While the system is stopped, initiate a Reset command. • Verify proper machine status and safety application program status Rockwell Automation Publication 35-UM001G-EN-P - September 2024 Test Status Appendix A Safe Brake Control Integrated Safety Instruction Validation Checklist Use the Safe Brake Control (SBC) instruction checklist in Table 109 to verify normal operation and the abnormal operation scenarios. IMPORTANT Perform I/O verification and validation before validating your safety ladder program. When possible, use immediate operands for instructions to reduce the possibility of systematic errors in your ladder program. Instruction operands must be verified for your safety ladder program. Table 109 - SBC Instruction Checklist Test Type Normal Operation Abnormal Operation Test Description Verify that the brake feedback is properly wired to the input module as documented. Initiate a Start command. • Verify that the machine is in a normal machine run condition • Verify proper machine status and safety application program status Set up a trend with expected time scale and the following tags to graphically capture this information: • SBC_Name.BO1 • SBC_Name.BO2 • SBC_Name.TOR • Device_Name.STOOutput Initiate an SBC request and initiate the STO event. • Verify the expected coordination of the STO output initiation and the SBC_Name.BO1 and SBC_Name.BO2 outputs • Verify proper machine status and safety application program status While the system is stopped, initiate a Start command. • Verify that the system remains de-energized for a normal safe condition • Verify proper machine status and safety application program status While the system is stopped, initiate a Reset command. • Verify that the system remains de-energized for a normal safe condition • Verify proper machine status and safety application program status Verify that brake feedback is properly wired to the input module as documented. Initiate a Start command. • Verify that the machine is in a normal machine run condition • Verify proper machine status and safety application program status Initiate machine function to make sure that the brake is released. Set up a trend with expected time scale and the following tags to graphically capture this information: • SBC_Name.BO1 • SBC_Name.BO2 • SBC_Name.TOR • Device_Name:STOOutput Remove brake feedback wires from the input module. • Verify that the appropriate diagnostic code is generated • Verify that the brake output SBC_Name.BO1 and SBC_Name.BO2 bits clear • Verify the external brake engagement While the system is stopped with the sensor subsystems in a safe state, initiate a Start command. • Verify proper machine status and safety application program status While the system is stopped, initiate a Reset command. • Verify proper machine status and safety application program status Rockwell Automation Publication 35-UM001G-EN-P - September 2024 Test Status 249 Appendix A Integrated Safety Instruction Validation Checklist Notes: 250 Rockwell Automation Publication 35-UM001G-EN-P - September 2024 Appendix B Configure a Message Instruction Overview A message instruction (MSG) is used to transfer data that does not require continuous updates. You can use it to configure and monitor the parameters/attributes of a dependent device on the network. IMPORTANT A message instruction must not be used for any safety-related function. Before you can configure an MSG instruction, you must create a tag with the MESSAGE data type to use in your logic program. The MSG (message) instruction handles all messaging that is initiated by a Logix Designer program. It automatically creates and manages TCP connections and CIP encapsulation sessions. For details on how to use MSG instructions, see Logix 5000 Controllers Messages Programming Manual, publication 1756-PM012. Message Process Figure 91 - Message Process Box 1 2 3 4 5 Description Format the required data and configure the ladder logic program to send a Message Request to the scanner or bridge module (download). The scanner or bridge module transmits the Message Request to the dependent device over the EtherNet/IP network. The dependent device transmits the Message Response back to the scanner. The data is stored in the scanner buffer. The controller retrieves the Message Response from the buffer of the scanner (upload). The Message is complete. The details of each step vary depending on the controller. See the product documentation for your controller. Rockwell Automation Publication 35-UM001G-EN-P - September 2024 251 Appendix B Configure a Message Instruction Figure 92 - ControlLogix Message Format in Studio 5000 For supported classes, instances, and attributes, see Armor PowerFlex AC Drives CIP Objects and Attributes Reference Data, publication 35-RD001. Box 1 2 3 4 5 6 7 8 9 10 11 252 Description Message Type The message type is usually CIP Generic. Service Type The service type indicates the service (for example, Get Attribute Single or Set Attribute Single) that you want to perform. Service Code The service code is the code for the requested EtherNet/IP service. This value changes based on the Service Type that has been selected. In most cases, this is a read-only box. If you select “Custom” in the Service Type box, then you must specify a service code in this box (for example, 4B for a Get Attributes Scattered service or 4C for a Set Attributes Scattered service). Class The class is an EtherNet/IP class. Instance The instance is an instance (or object) of an EtherNet/IP class. Attribute The attribute is a class or instance attribute. Source Element This box contains the name of the tag for any service data to be sent from the scanner or bridge to the module and drive. Source Length This box contains the number of bytes of service data to be sent in the message. Destination This box contains the name of the tag that receives service response data from the module and drive. Path The path is the route that the message follow.s Note: Click Browse to find the path or type in the name of a module that you previously mapped. Name The name for the message. Rockwell Automation Publication 35-UM001G-EN-P - September 2024 Appendix B Configure a Message Instruction Example: Read SS1 Fault Type In the drive module, the connection to the safety instance or instances is controlled by a safety supervisor. The supervisor status is read by the safety controller through the Safety Input Assembly or by an explicit message. Table 110 - Safe Stop 1 Fault Type: MSG Parameter Service Code Value 0x0E Class 0x5A Description Get attribute single Safety Stop Functions Object Instance Attribute Data Type 1 0x11C USINT SS1 Fault Type Unsigned short integer Rockwell Automation Publication 35-UM001G-EN-P - September 2024 253 Appendix B Configure a Message Instruction Notes: 254 Rockwell Automation Publication 35-UM001G-EN-P - September 2024 Index A Automatic Device Configuration (ADC) how to use 205 Add-On Profile (AOP) with ADC 205 ArmorConnect cable ratings 50 power media 56 C cable system overview non-safety version 65 catalog number explanation Bulletin 281E 19 checklist. See validation checklist CIP messaging 140 circuit error 140 configuration error 139 configuration tool 205 connection idle action 106 loss action 106 connections Ethernet and I/O 57 power 57 control module LED status and reset 25 controller I/O data 137 controller-based instruction 124 D disable the Ethernet port on port configuration tab 215 with a MSG instruction 218 discrepancy error 140 discrepancy time 132, 133, 134 drive safety instruction 124 dual channel error 140 mode 141, 142 dual-channel mode 132, 141 E electromagnetic compatibility (EMC) general notes (Bulletin 284E only) 46 wiring 47 Explicit Message configuration 251 F fault 129 recovery 140 safety core 127 SS1 128 SS2, SOS, SBC, SLS, SLP, SDI 129 STO 127 fault detection 134 feature gland plate entrance 28 G group motor installation for USA and Canada 49 I input assembly tag 137, 138, 139, 143, 144, 145 latch error time 132 signal lines 136 input valid (safety) 138 installation 35 integrated STO state reset 130 integrated safety instruction validation checklist 243 L latch error time 142 M mission time 94 monitored SS1 114, 196, 197 motor cable considerations 49 mount orientation 50 N no test pulse mode 117 not used 117 O off-delay 135 output assembly tag 106, 111, 116, 117 output monitor value 144 P PFD 95 PowerFlex 755 drive 94 Rockwell Automation Publication 35-UM001G-EN-P - September 2024 255 Index PFH 95 PowerFlex 755 drive 94 power supply output mode 145 product description 15 overview 15 pulse period 135, 143 pulse width 135, 143 R receiving 35 redundant channel safety devices 132 response time 143 S safety brake 120 core fault 127 feedback 129 feedback fault 129 input alarm 139 input alarm recovery 140 input status 137 input valid 138 input value 138 output data 143 output ready 144 output status 143 output with test pulse 143 supervisor state 126 supervisor state 126 SBC 116, 128, 249 activated by STO 119 activation 116 control mode 117 fault 120, 129 reset 116 validation checklist 249 SDI 247 fault 129 validation checklist 247 secure applications disable the Ethernet port on port configuration tab 215 with a MSG instruction 218 SFX 248 validation checklist 248 shield and grounding of motors and motor cables 49 short-circuit between input signal lines 136 single feedback monitoring 95 safely-limited position (SLP) 246 fault 129 validation checklist 246 safely-limited speed (SLS) 245 example 125 fault 129 validation checklist 245 256 Rockwell Automation Publication 35-UM001G-EN-P - September 2024 SOS fault 129 SS1 111, 128, 196, 243 activation 111 fault 128 reset 111 safety fault 112 validation checklist 243 SS2 fault 129 standstill speed 197 status data input and controller 137 STO 106 activates SBC 119, 195 delay 108, 109 fault 110, 127 operation 108 reset 107 state reset 130 to SBC Delay 195 STO fault message Circuit Err(3) 127 Stuck High(5) 127 storing 35 T test output mode 145 test pulse 135, 143 test pulses mode 117 timed SS1 113, 196 U unpacking 35 unshielded cable 49 used no test pulse mode 117 test pulses mode 117 V validation checklists 243, 245, 246, 247, 248, 249 W wiring examples door monitor 148 emergency stop switch 88, 148 reset switch 88, 148, 149 wiring guidelines 46 Armor PowerFlex AC Drives User Manual Notes: Rockwell Automation Publication 35-UM001G-EN-P - September 2024 257 Rockwell Automation Support Use these resources to access support information. 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Waste Electrical and Electronic Equipment (WEEE) At the end of life, this equipment should be collected separately from any unsorted municipal waste. Rockwell Automation maintains current product environmental compliance information on its website at rok.auto/pec. Allen-Bradley, Armor, ArmorConnect, ArmorPower, ArmorStart, ArmorStratix, CompactLogix, ControlFLASH, ControlFLASH Plus, ControlLogix, expanding human possibility, FactoryTalk, GuardLogix, Kinetix, Logix 5000, On-Machine, PowerFlex, ProposalWorks, Rockwell Automation, RSLinx, Safety Automation Builder, Studio 5000, and Studio 5000 Logix Designer are trademarks of Rockwell Automation, Inc. CIP, CIP Safety, CIP Security, DeviceNet, and EtherNet/IP are trademarks of ODVA, Inc. Windows is a trademark of Microsoft. Electrical Standard for Industrial Machinery, National Electrical Code, NEC, and NFPA are trademarks of the National Fire Protection Association. HARTING is a trademark of HARTING Technology Group. 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