Rockwell Automation Publication SAFETY-AT140A-EN-P - May 2015 13
Safety Function: Actuator Subsystems – Stop Category 1 via the PowerFlex 525 and PowerFlex 527 Drives with Safe Torque-off
Configure the PowerFlex 525 Drive
The PowerFlex 525 drive is configured by using Connected Components Workbench™ software, version 7 or later. A
detailed description of how to fully configure the PowerFlex 525 drive is beyond the scope of this document. For more
information about this drive, refer to the PowerFlex 520-Series Adjustable Frequency AC Drive User Manual, publication
520-UM001
The PowerFlex 525 drive must have the following four parameters adjusted to perform as intended in the document.
Parameters 46, 62, and 63 must be set as above for the Start/Stop button to operate as intended.
Parameter 105 configures the PowerFlex 525 drive to accept the STO inputs without generating a spurious F111 fault.
By default, the PowerFlex 525 drive provides a coast-to-stop in response to an STO input. This action overrides any other
stop type that might be configured for the drive for its normal production stop.
Configure the PowerFlex 527 Drive
The PowerFlex 527 drive is configured by using Studio 5000 Automation Engineering & Design Environment™. A detailed
description of how to fully configure the PowerFlex 527 drive is beyond the scope of this document. For more information
about this drive, refer to PowerFlex 527 Adjustable Frequency AC Drive User Manual, publication 520-UM002
.
By default, the PowerFlex 527 drive provides a coast-to-stop in response to an STO input. This action overrides any other
stop type that might be configured for the drive for its standard stop.
For a stop category 1, after a demand, an immediate controlled stop should be executed using a Motion Axis Stop or
Motion Servo Off command.
Calculation of the Performance Level
When properly implemented, both the PowerFlex 525 and PowerFlex 527 drives with safe torque-off (STO) can be used in
a safety function that has a Performance Level required (PLr) rating of Category 3, Performance Level d (CAT. 3, PLd),
according to ISO 13849-1: 2008, as calculated by using the Safety Integrity Software Tool for the Evaluation of Machine
Applications (SISTEMA).
Both the PowerFlex 525 and PowerFlex 527 drives ship with the STO feature disabled by jumpers. Refer to the appropriate user
manual for guidance on removing these jumpers.
Parameter # Name Value Units Internal Value Default Min. Max
46 Start Source 1 EtherNet/I: 5 Keypad 1 5
62 Digin TermBlk 02 3-Wire Start 49 2-Wire FWD 0 49
63 Digin TermBlk 03 3-Wire Dir 51 2-Wire REV 0 51
105 Safety Open En FaultDisable 1 FaultEnable 0 1
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