Allen-Bradley PowerFlex 755 User manual

PowerFlex 755/755T Integrated Safety Functions
Option Module
Catalog Number 20-750-S4
User Manual
Original Instructions

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.
Labels may also be on or inside the equipment to provide specific precautions.
WARNING: Identifies information aboutpractices 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 iscritical for successful application and understanding of the product.
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.
BURNHAZARD: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
potentialArcFlash.ArcFlashwillcausesevereinjury or death. WearproperPersonalProtectiveEquipment(PPE).FollowALL
Regulatory requirements for safe work practices and for Personal Protective Equipment (PPE).

Rockwell Automation Publication 750-UM005A-EN-P - October 2018 3
TableofContents
Preface
Conventions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Terminology. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Product Firmware and Release Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Additional Resources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Chapter 1
AboutSafeStopandSafeMonitor
Functions What Is the Integrated Safety Functions Option Module? . . . . . . . . 15
Compatible Drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Compatible Safety Controllers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Safety Application Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Safety Certification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Important Safety Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Stop Category Definitions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Performance Level and Safety Integrity Level (SIL) CL3 . . . . . . 19
Proof Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
PFD and PFH Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
PFD and PFH Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Safety Data for Safe Torque Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Safety Data for Safe Feedback. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Safety Data for Safety I/O. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Spurious Trip Rate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Safety Reaction Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Considerations for Safety Ratings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Encoder Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Supported Encoders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Encoder Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
General Encoder Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Digital AqB Diagnostics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Sine/Cosine and Hiperface Diagnostics . . . . . . . . . . . . . . . . . . . . . 27
Contact Information If Safety Option Failure Occurs . . . . . . . . . . . . 29
Chapter 2
Installation Remove Power to the System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Access the Control Pod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Set the SAFETY and Hardware ENABLE Jumpers . . . . . . . . . . . . . . 33
Install the Safety Option Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Feedback Installation Guidelines. . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
I/O Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Cabling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Power Supply Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

4Rockwell Automation Publication 750-UM005A-EN-P - October 2018
Table of Contents
Chapter 3
Safety I/O Safety Inputs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Safety Input Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Latch Input Error Operation in Single Channel Mode. . . . . . . . 41
Single Channel Safety Input Status Data. . . . . . . . . . . . . . . . . . . . . 42
Dual-channel Safety Input Operation . . . . . . . . . . . . . . . . . . . . . . . 43
Equivalent Dual-channel Input Operation. . . . . . . . . . . . . . . . . . . 44
Complementary Dual-channel Input Operation . . . . . . . . . . . . . 45
Standard Input Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Safety Input Safety Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Safety Input Alarms. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Determining Safety Input Alarm Type . . . . . . . . . . . . . . . . . . . . . . 50
Safety Input Alarm Recovery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Input Delays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Use With PowerFlex 750-Series ATEX Option Module . . . . . . 52
Safety Outputs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Safety Output with Test Pulse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Single-channel Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Latch Output Error Operation in Single Channel Mode . . . . . . 54
Dual-channel Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Latch Output Error Operation in Dual Channel Mode . . . . . . . 55
Safety Output Safety Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Commanding Safety and Test Outputs. . . . . . . . . . . . . . . . . . . . . . 59
Safety Output Alarms. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Determining Safety Output Alarm Type . . . . . . . . . . . . . . . . . . . . 61
Safety Output Alarm Recovery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Test Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Standard Output Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Test Output Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Power Supply Output. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Test Output Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Test Output Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Test Output Ready . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Chapter 4
Drive-based Safe Stop Functions Safety Output Assembly Safe Stop Function Tags. . . . . . . . . . . . . . . . 67
Safety Input Assembly Safe Stop Function Tags. . . . . . . . . . . . . . . . . . 68
Safety Function in Response to Connection Event . . . . . . . . . . . . . . . 70
Connection Loss Action . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Connection Idle Action. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Safe Torque Off Function. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Safe Torque Off Activation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Safe Torque Off Reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Safe Torque Off Delay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Safe Torque Off Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Safe Torque Off Stopping Action and Source . . . . . . . . . . . . . . . . 76

Rockwell Automation Publication 750-UM005A-EN-P - October 2018 5
Table of Contents
STO Safety Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Safe Stop 1 Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Safe Stop 1 Activation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Safe Stop 1 Reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Safe Stop 1 Stopping Action and Source . . . . . . . . . . . . . . . . . . . . . 80
Timed Safe Stop 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Monitored Safe Stop 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
SS1 Safety Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Safe Brake Control Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Safe Brake Control Activation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Safe Brake Control Reset. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Safe Brake Control Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Safe Brake Control Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
SBC Safety Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Connecting a Safety Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Chapter 5
Controller-based Safety
Functions Drive Safety Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Before Adding the Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . 97
Drive Safety Instruction Example . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Pass-through Data Using Standard I/O Mode . . . . . . . . . . . . . . . . . . . 98
Pass-through Data Using Integrated Motion. . . . . . . . . . . . . . . . . . . . 100
SFX Instruction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
SFX Instruction Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Chapter 6
Standard I/O Mode –
Configuration, Programming,
and Operation
Safety Assembly Tags . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Configure Safety in the Logix Designer Application . . . . . . . . . . . . . 106
Add a PowerFlex 755 Drive/755T Drive Product to the
Safety Controller Project. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
Add an Option Module to a PowerFlex 755 Drive. . . . . . . . . . . 108
Generate the Safety Network Number (SNN) . . . . . . . . . . . . . . 110
Safety Configuration Signature and Ownership . . . . . . . . . . . . . 125
Reset Ownership . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
Safety Tags in Standard Routines . . . . . . . . . . . . . . . . . . . . . . . . . . 126
Standard Tags in Safety Routines (tag mapping). . . . . . . . . . . . . 126
Standard and Safety Tasks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
Safety Function Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
Pass-through Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
Falling Edge Reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
Understand Integrated Safety Drive Replacement. . . . . . . . . . . . . . . 129
Replace an Integrated Safety Drive in a GuardLogix System . . 130
PowerFlex 755 IO Mode Using SFX, SS1, and SLS Instructions. . 132
Studio 5000 Logix Designer Application Configuration . . . . . 132
Programming Example. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135

6Rockwell Automation Publication 750-UM005A-EN-P - October 2018
Table of Contents
Chapter 7
Integrated Motion –
Configuration, Programming,
and Operation
Safety Assembly Tags . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
Configure the Integrated Safety Function Option Module in the
Logix Designer Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
Add a PowerFlex 755 Drive to the Controller Project. . . . . . . . 144
Understand Module Properties Categories . . . . . . . . . . . . . . . . . . . . . 145
Module Properties>General Category. . . . . . . . . . . . . . . . . . . . . . 146
Module Properties>Connection and Safety Categories . . . . . . 149
Motion Safety>Actions Category . . . . . . . . . . . . . . . . . . . . . . . . . . 152
Motion Safety>Primary Feedback Category . . . . . . . . . . . . . . . . 153
Motion Safety>Secondary Feedback Category . . . . . . . . . . . . . . 155
Motion Safety>Scaling Category. . . . . . . . . . . . . . . . . . . . . . . . . . . 156
Motion Safety>Discrepancy Checking Category . . . . . . . . . . . . 157
Motion Safety>STO Category. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
Motion Safety>SS1 Category. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
Motion Safety>SBC Category . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
Motion Safety>Input Configuration Category. . . . . . . . . . . . . . 161
Motion Safety>Test Output Category . . . . . . . . . . . . . . . . . . . . . 162
Motion Safety>Output Configuration Category . . . . . . . . . . . . 163
Axis Properties > Actions > Safety Actions . . . . . . . . . . . . . . . . . 164
Module Properties > Associated Axes Motor and Load
Feedback Device. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
Generate the Safety Network Number (SNN) . . . . . . . . . . . . . . 166
Safety Configuration Signature and Ownership . . . . . . . . . . . . . 167
Reset Ownership . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
Replace an Integrated Safety Drive in a GuardLogix System . . 168
Motion Direct Commands in Motion Control Systems. . . . . . 169
Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
Motion and Safety Tasks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
Motion Safety Instances. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
Safety Function Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
Safe Monitor Network Communication. . . . . . . . . . . . . . . . . . . . 179
Explicit Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
Application Example - Using SFX, SS1, and SLS Instructions
with Integrated Motion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
Studio 5000 Logix Designer Application Configuration . . . . . 185
Programming Example. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
Chapter 8
Monitoring and Troubleshooting Monitor Status Using Status Indicators . . . . . . . . . . . . . . . . . . . . . . . . 195
Module Status Indicator (DS1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196
Network Status Indicator (DS2). . . . . . . . . . . . . . . . . . . . . . . . . . . 196
Motion Output Status Indicator (DS3) . . . . . . . . . . . . . . . . . . . . 197
Safety Fault Indicator (DS4). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197
Safety Fault Names . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197
Understand Safety Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199

Rockwell Automation Publication 750-UM005A-EN-P - October 2018 7
Table of Contents
Safety Supervisor State . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199
Safety Core Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199
Safe Torque Off Fault. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200
Safe Stop 1 Fault. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
Safe Brake Control Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
SS2, SOS, SLS, SLP, and SDI Faults. . . . . . . . . . . . . . . . . . . . . . . . 202
Safety Feedback Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
Safety Fault Reset. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
Monitor Status with a HIM or Software. . . . . . . . . . . . . . . . . . . . . . . . 205
Fault Messages on HIM, Drive Module, and Connected
Components Workbench Software . . . . . . . . . . . . . . . . . . . . . . . . 205
Monitor Status Using Integrated Motion . . . . . . . . . . . . . . . . . . . . . . 210
Out-of-Box State. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214
Recognize Out-of-Box State . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214
Restore the Drive to Out-of-Box State. . . . . . . . . . . . . . . . . . . . . . 214
Appendix A
Safety Function Validation
Checklist Safe Stop 1 (SS1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218
Safe Stop 2 (SS2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220
Safe Operating Speed (SOS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223
Safely-limited Speed (SLS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225
Safely-limited Position (SLP). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226
Safe Direction (SDI) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228
Safe Feedback Interface (SFX). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229
Safe Brake Control (SBC). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231
Appendix B
Specifications,Certifications,and
CE Conformity Integrated Safety Functions Option Module Specifications . . . . . . 233
Electrical Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234
Environmental Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235
Certifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236
CE Conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236
Machinery Directive (2006/42/EC) . . . . . . . . . . . . . . . . . . . . . . . 236
EMC Directive (2014/30/EU) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237
Waste Electrical and Electronic Equipment (WEEE) . . . . . . . . 237
Appendix C
Safety I/O Assemblies and Safety
Attributes Safety Assembly Tags . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240
Safety Feedback Attributes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245
Safe Stop Function Attributes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 247
Explicit Messages. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 251
Example: Read SS1 Fault Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . 251

8Rockwell Automation Publication 750-UM005A-EN-P - October 2018
Table of Contents
Appendix D
Parameter Data Parameters and Settings in a Linear List . . . . . . . . . . . . . . . . . . . . . . . . 253
Device Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 253
Host Config Parameters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 259
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 263

Rockwell Automation Publication 750-UM005A-EN-P - October 2018 9
Preface
This user manual explains how to use PowerFlex® 755 drives and PowerFlex
755T drive products in safety applications up to safety integrity level 3 (SIL 3),
performance level e (PLe), category 4.
This user manual is intended for people that design, install, configure, or
troubleshoot safety applications that use the Integrated Safety Functions
option module (catalog number 20-750-S4).
This user manual covers using network safety with drives in Standard I/O
mode and Integrated Motion mode. All chapters apply to both modes with the
following exceptions:
•Chapter 6 is specific to Standard I/O mode and can be skipped if you are
using Integrated Motion mode.
•Chapter 7 is specific to Integrated Motion mode and can be skipped if
you are using Standard I/O mode.
This user manual describes the safety requirements, including probability of
dangerous failure on demand (PFD) and average frequency of a dangerous
failure (PFH) per hour values and application verification information (see
PFD and PFH Data on page 21).
Conventions This manual lists identifies parameter names by listing the parameter number
first, followed by the name in brackets. For example, P7 [STO Fault Type].
Both the Host Config and Device Config parameters exist for this option
module and the parameter numbers overlap. For example, there is a P3 [Device
Config Identity State] and a P3 [Host Config Safety State]. Host Config
parameters reside on the Host (that is, the drive) side of the option module and
are specific to supporting the option module. Device Config parameters reside
on the option module itself.
Throughout this manual, the PowerFlex 755/755T Integrated Safety
Functions option module is also referred to as the Integrated Safety Functions
option module.
Topic Page
Conventions 9
Terminology 10
Product Firmware and Release Notes 12
Additional Resources 13
IMPORTANT You must have a basic understanding of electrical circuitry and familiarity
withPowerFlex755 drivesand PowerFlex755Tdriveproducts. You mustalso
be trained and experienced in the creation, operation, and maintenance of
safety systems.

10 Rockwell Automation Publication 750-UM005A-EN-P - October 2018
Preface
Throughout this manual, the PowerFlex 755TL low harmonic drives,
PowerFlex 755TR regenerative drives, PowerFlex 755TM drive systems are
also referred to as PowerFlex 755T drive products.
The PowerFlex 755 drive is used for the examples in this manual.
Terminology Table 1 defines the abbreviations that are used in this manual.
Table 1 - Abbreviations and Definitions
Abbreviation Full Term Definition
Timed SS1 Timed Safe Stop 1 Timed SS1 and Safe Stop 1 time-controlled (SS1-t) are synonymous. Both mean a safe stop where the
motor speed is decelerated to zero and once the maximum stop-time elapses, torque is removed from
the motor.
• Safe Stop 1 time-controlled (SS1-t) is according to IEC 61800-5-2.
SS1-t Safe Stop 1 time-controlled
Monitored SS1 Monitored Safe Stop 1 Monitored SS1and SafeStop1ramp-monitored(SS1-r) aresynonymous.Bothmeanasafestopwhere
themotor speed is reducedtostandstillwithindecelerationlimits and oncestandstillspeedis reached
or the maximum stop-time elapses, torque is removed from the motor.
• Safe Stop 1 ramp-monitored (SS1-r) is according to IEC 61800-5-2.
SS1-r Safe Stop 1 ramp-monitored
1oo2 One out of Two Refers to the behavioral designof a dual-channel safety system.
CAT Category Classification of the safety-related parts of a control system in respect of their resistance to faults and their subsequent behavior in the fault condition, and which is achieved bythe structural arrangement
of the parts, fault detection, and/or by their reliability (source ISO 13849-1).
CL Claim Limit ThemaximumSILratingthatcanbeclaimedforasafety-relatedelectricalcontrolsystemsubsystemin
relation to architecturalconstraints and systematic safety integrity (sourceIEC 62061).
CIP™ Common Industrial Protocol Protocol for industrial automation applications and trademarked by ODVA, Inc.
EN European Norm The official European Standard.
ESD Emergency Shutdown Systems A system, usually independent of the main control system, which is designed toshut down an
operating system safely.
ESPE Electro-sensitive Protective Equipment
An assembly of devices and/or components working together for protective tripping or presence-
sensing purposes and includes as a minimum:
•Asensingdevice.
• Controlling/monitoring devices.
• Output signal-switching devices (OSSD).
HFT Hardware Fault Tolerance The HFT equals n, where n+1 faults could cause the loss of the safety function. An HFT of one means
that two faults are required before safety is lost.
HIM Human Interface Module A module that is used to configure a device.
IEC International Electrotechnical Commission The International Electrotechnical Commission (IEC) is the organization that prepares and publishes
international standards for all electrical, electronic, and related technologies.
IGBT Insulated Gate Bi-polar Transistors Typical power switch that is used to control main current.
ISO International Organization for Standardization The International Organization for Standardization is an international standard-setting body that is
composed of representatives from various national standards organizations.
NC Normally Closed A set of contacts on a relay or switch that are closed when the relay is de-energized or the switch is de-
activated.
NO Normally Open A set of contacts on a relay or switch that are open when therelay is de-energized or the switch is de-
activated.
OSSD Output Signal Switching Device The component of the electro-sensitive protective equipment (ESPE) connected to the control system of a machine. When the sensing device is actuatedduring normal operation, the device responds by
going to the OFF-state.
PELV Protective Extra Low Voltage An electrical system where the voltage cannot exceed ELV under normal conditions, and under single-
fault conditions, except earth faults in other circuits.

Rockwell Automation Publication 750-UM005A-EN-P - October 2018 11
Preface
PES Programmable Electronic Systems System for control, protection, or monitoring based on one or moreprogrammable electronic devices, including all elements of the system such as power supplies, sensors and other input devices, data
highways and other communication paths, and actuatorsand other output devices.
PFD Probability of Dangerous Failure on Demand The average probability of a system to fail to perform its design function on demand.
PFH Average Frequency of a Dangerous Failure per hour The average frequency of a system to have a dangerous failure per hour.
PL Performance Level EN ISO 13849-1 safety rating
PM Permanent Magnet In permanent magnet (PM) motors, magnets mounted on or embeddedin the rotor, couple withthe
current-induced internal magnetic fields of the motor generated by electrical input to the stator.
SBC Safe Brake Control Controls safety discrete outputs that actuate a brake. Sets timing between brake and Safe Torque Off.
SDI Safe Direction Monitors position of a motor to detect movement of more than a defined amount in the unintended
direction.
SELV Safety Extra Low Voltage Circuit Asecondarycircuitthatisdesignedandprotectedso that,undernormalandsinglefaultconditions,its
voltages do not exceed a safe value.
SFX Safety Feedback Interface A GuardLogix® Drive Safety interface that scales feedback position into position units and feedback velocity into position units per time unit. Feedback Position and Velocity are read from a Safety Input
assembly to an integrated Safe Speed drive.
SIL Safety Integrity Level A measure of a products ability to lower the risk that a dangerous failure could occur.
SLP Safely-Limited Position Monitors the position of a motor to ensure that the positon does not deviate above or below defined
limits.
SLS Safely-Limited Speed Monitorsthespeed ofa motor and sets the SLS Limit output ifthespeed exceeds the ActiveLimitinput
value.
SNN Safety Network Number Uniquely identifies a network across all networks in the safety system. You are responsible for
assigning a unique number for each safety network or safety subnet within a system.
SOS Safe Operating Stop Monitorsthespeed or position of a motortoensurethatthedeviationfromstandstill speedorposition
is not more than a defined amount.
SS1-r Safe Stop 1 Ramp Monitored
Safe stop where the motor speed is decelerated to zero and once the maximum stop-time elapses,
torque is removedfrom the motor.
SafeStop1ramp-monitored(SS1-r) isaccordingtoIEC61800-5-2andisStopCategory1,as defined in
IEC 60204
SS1-t Safe Stop 1 Time Controlled
Safe stop where the motor speed is reduced to standstill within deceleration limits and once standstill
speed is reached or the maximum stop-time elapses, torque is removed from the motor.
Safe Stop 1 time-controlled (SS1-t) is according to IEC 61800-5-2 and is Stop Category 1, as defined in
IEC 60204
STO Safe Torque Off
The Safe Torque Off (STO) function is used to help prevent unexpected motor rotation during an
emergency while the drive remains connected to the power supply. When STO is activated, the torque
power cannot reach the drive, which stops and prevents any motor shaft rotation.
Safe Torque Off (STO) is according to IEC 61800-5-2 and is Stop Category 0 as defined in IEC 60204.
Table 1 - Abbreviations and Definitions (continued)
Abbreviation Full Term Definition

12 Rockwell Automation Publication 750-UM005A-EN-P - October 2018
Preface
Product Firmware and
Release Notes
Product firmware and release notes are available online within the Product
Compatibility and Download Center.
1. From the Search bar on http://www.ab.com, choose Compatibility and
Downloads.
2. Search for your product.
3. On the search results page, find the firmware and release notes for your
product. If no firmware/release notes are available, the module is still
shipping with its original firmware release.
See the Product Compatibility and Download Center Quick Start Guide,
publication PCDC-QS001, for instructions on how to find and download
firmware and release notes.
IMPORTANT Both standard connections to the drive and safety connections to the card
must be closed to update the Integrated Safety Functions Module.

Rockwell Automation Publication 750-UM005A-EN-P - October 2018 13
Preface
Additional Resources These documents contain additional information concerning related Rockwell
Automation products.
You can view or download publications at
http://www.rockwellautomation.com/global/literature-library/overview.page.
To order paper copies of technical documentation, contact your local
Allen-Bradley distributor or Rockwell Automation sales representative.
Resource Description
PowerFlex 750-Series Products with TotalFORCE® Control Installation
Instructions, publication 750-IN100 Provides the basic steps toinstall PowerFlex 755TL low harmonic drives, PowerFlex 755TR
regenerative drives, and PowerFlex 755TM drive systems.
PowerFlex 755TM IP00 Open Type Kits Installation Instructions, publication
750-IN101 Provides instructions to install IP00 Open Type kits in user-supplied enclosures.
PowerFlex Drives with TotalFORCE Control Programming Manual, publication
750-PM100 Provides detailed information on:
• I/O, control, and feedback options
• Parameters and programming
• Faults, alarms, and troubleshooting
PowerFlex 750-Series AC Drive Installation Instructions, publication 750-IN001 Provides information on how to install the Safe Torque Off option module in PowerFlex 750-
Seriesdrive.
PowerFlex 750-Series AC Drives Programming Manual, publication 750-PM001 Provides information on how to mount, install, and configure PowerFlex 750-Series drives.
Enhanced PowerFlex 7-Class Human Interface Module (HIM) User Manual,
publication
20HIM-UM001 Provides information for using the 20-HIM-A6 HIM module to configure PowerFlex 750-Series drives and the Safe Torque Off option module.
GuardLogix Safety Application Instruction Set Reference Manual,
publication 1756-RM095 Provides information that describes the GuardLogix Safety Application Instruction set.
System Design for Control of Electrical Noise Reference Manual,
publication GMC-RM001 Information,examples,andtechniquesthataredesignedtominimizesystem failures caused by electrical noise.
Safety Guidelines for the Application, Installation, and Maintenance of
Solid-State Control, publication
SGI-1.1 Describes important differences between solid-state control and hardwired electromechanical devices.
GuardLogix 5580 and Compact GuardLogix 5380 Controller Systems Safety
Reference, publication 1756-RM012 Provides information on safety application requirements for GuardLogix 5580 and Compact GuardLogix 5380 controllers in Studio 5000 Logix Designer® applications.
ControlLogix® 5580 Controllers User Manual, publication 1756-UM543 Provides information on how to use standard ControlLogix 5580 controllers.
CompactLogix™5380 ControllersUser Manual, publication 5069-UM001 Provides information on how to use standard CompactLogix 5380 controllers.
Product Certification Website,
www.rockwellautomation.com/global/certification/overview.page Provides declarations of conformity, certificates, and other certification details.

14 Rockwell Automation Publication 750-UM005A-EN-P - October 2018
Preface
Notes:

Rockwell Automation Publication 750-UM005A-EN-P - October 2018 15
Chapter 1
About Safe Stop and Safe Monitor Functions
This chapter provides information on safety considerations for the Integrated
Safety Functions option module.
What Is the Integrated
Safety Functions Option
Module?
The Integrated Safety Functions option module provides a networked STO
(Safe Torque Off) function via an EtherNet/IP® network. It is also equipped
for Integrated (drive-based) Timed SS1, Monitored SS1, and Safe Brake
Control, which operate in the drive and are activated through the network
safety connection.
The Integrated Safety Functions option module also supports select controller-
based IEC 61800-5-2 safety functions operating in GuardLogix® 5580 or
Compact GuardLogix 5380 controllers that use the EtherNet/IP network to
communicate with the safety I/O. This support includes the new safety
function instructions that are provided on the Drive Safety tab in the Logix
Designer application.
The Integrated Safety Functions option module includes these features:
• Is designed to remove power from the gate firing circuits of the drive
output power devices (IGBTs). With the power removed, the drive
output power devices cannot turn on to generate AC power to the
motor.
• Can be used in combination with other safety devices to satisfy the
requirements of IEC 61508, IEC 61800-5-2 SIL 3, ISO 13849-1 PLe,
and Category 4 for Safe Torque Off (STO).
Topic Page
What Is the Integrated Safety Functions Option Module? 15
Compatible Drives 17
Compatible Safety Controllers 17
Safety Application Requirements 18
Safety Certification 18
Proof Tests 20
PFD and PFH Definitions 20
PFD and PFH Data 21
Safety Reaction Time 24
Contact Information If Safety Option Failure Occurs 29

16 Rockwell Automation Publication 750-UM005A-EN-P - October 2018
Chapter 1 About Safe Stop and Safe Monitor Functions
When used for safe speed monitoring, the drive can be configured for single- or
dual-feedback to achieve the following safety ratings:
• Single-feedback configurations using safety encoders provide up to SIL
2 PLd capability.
• Dual-feedback configurations provide up to SIL 3 PLe capability when
discrepancy testing (either velocity, position, or both) is enabled. Safety
functions that use position check have up to SIL 2 PLd capability. In this
configuration, at least one encoder (the primary encoder) has to comply
with SIL 2, PL d. The second encoder can be a standard encoder.
IMPORTANT The Integrated Safety Functions option module is suitable for performing
mechanical work on the drive trainor affected area ofa machine only. It
does not provide electrical safety.
IMPORTANT The Integrated Safety Functions option module 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. See Remove Power to the System on page 32 for more
information.
IMPORTANT Multiple safety option modules in a singledrive are not allowed. Only one of
these safety option modules can be installed in the drive:
• PowerFlex® 750-Series Safe Torque Off option module
(catalog number 20-750-S)
• PowerFlex 750-Series Safe Speed Monitor option module
(catalog number 20-750-S1)
• PowerFlex 755/755T Integrated Safety - Safe Torque Off option module
(catalog number 20-750-S3)
• PowerFlex755/755TIntegratedSafetyFunctionsoptionmodule(catalog
number 20-750-S4)
ATTENTION: If two output IGBTs fail in the drive, when the Integrated Safety
Functionsoptionmodule has controlledthe drive outputs to the Offstate,the
drivecan provide stored energy for up to 180° of rotation in a 2-pole motor
before torque production in the motor stops.
ATTENTION: The STO function only disables motor torque. A mechanical
forceon the motorshaft such as suspendedloads,back pressureinapump or
fan, can cause motor rotation.

Rockwell Automation Publication 750-UM005A-EN-P - October 2018 17
About Safe Stop and Safe Monitor Functions Chapter 1
Compatible Drives The Integrated Safety Functions option module is compatible with these
PowerFlex 755 drives and PowerFlex 755T drive products:
• PowerFlex 755 drives (v14.xxx or later)
• PowerFlex 755TL low harmonic drives (v4.xxx or later)
• PowerFlex 755TR regenerative drives (v4.xxx or later)
• PowerFlex 755TM drive systems (v4.xxx or later)
Integrated safety functions are controlled via the embedded Ethernet port on
the drive only. The 20-750-ENETR can still be used, but only in conjunction
with the embedded Ethernet port by being in Tap mode (safety messages must
go through the embedded Ethernet port on drive).
The following Add-on Profiles (AOPs) are needed depending on the drive and
type of control used:
Compatible Safety
Controllers
A GuardLogix safety controller is required for use of the Integrated Safety
Functions option module that is used in Network mode control (‘Safety’,
‘Standard and Safety’, or ‘Motion and Safety’ used for Connection type). The
following GuardLogix controllers can be used:
IMPORTANT Do not use this option module as a control for starting or stopping the drive.
IMPORTANT The Integrated Safety Functions option module is not compatiblewith
PowerFlex 753 drives.
Product Standard Control Integrated Motion
755 v5.03 (or later) v9.00.00 (or later)
755T v5.04 (or later) Future
Controller Studio 5000 Logix Designer® Application Version / Controller Firmware
GuardLogix 5580 safety controller v31 (or later)
Compact GuardLogix 5380 safety controller v31 (or later)
IMPORTANT The Integrated Safety Functions option module is not supported by
GuardLogix 5570 and GuardLogix 5370 (or earlier) safety controllers.

18 Rockwell Automation Publication 750-UM005A-EN-P - October 2018
Chapter 1 About Safe Stop and Safe Monitor Functions
Safety Application
Requirements
Create, record, and verify the safety signature as part of the required safety
application development process. The safety controller creates the safety
signature, which 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.
If the Drive Safety Function Instructions are used in the safety application,
special consideration must be taken to verify the application. See Appendix A
for guidance on verifying the drive safety function instructions.
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 that are
listed in the Additional Resources on page 13.
Safety Certification The TÜV Rheinland group has approved the PowerFlex 755 Integrated Safety
Functions option module (catalog number 20-750-S4) as suitable for use in
integrated safety applications:
• Up to and including SIL 3 according to IEC 61508
• Up to and including SIL CL3 according to IEC 62061
• Up to and including PLe (Category 4) according to ISO 13849-1.
In these applications, the removal of motion-producing power is considered to
be the safe state. All components in the system must be chosen and applied
correctly to achieve the desired level of operator safeguarding.
Important Safety Considerations
You are responsible for these system safety considerations:
• Set-up, safety rating, and validation of any sensors or actuators
connected to the system.
• Complete a system-level risk assessment, and reassess the system any
time a change is made.
• Certification of the system to the desired safety Performance Level/
Safety Integrity Level.
• Project management and proof testing.
• Programming the application software and the safety option module
configurations in accordance with the information in this manual.
• Access control to the system.
• Analyze all configuration settings and choose the proper setting to
achieve the required safety rating.
• Validation and documentation of all safety functions used.
IMPORTANT Only qualified, authorized personnel that are trained and experienced in
functional safety can plan, implement, and apply functional safety systems.

Rockwell Automation Publication 750-UM005A-EN-P - October 2018 19
About Safe Stop and Safe Monitor Functions Chapter 1
Stop Category Definitions
There are three stop categories:
• 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. This can be
achieved using SS1 with STO.
• Stop Category 2 is a controlled stop with power left available to the
machine actuators. This can be achieved using controller-based SS2 /
SOS with the PowerFlex 755T drive products.
Performance Level and Safety Integrity Level (SIL) CL3
For safety-related control systems, Performance Level (PL), according to
ISO 13849-1, and SIL levels, according to IEC 61508 and EN 62061, include
a rating of the ability of the system 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 EN 62061 standards for complete
information on requirements for PL and SIL determination.
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.
IMPORTANT Whendesigningthe machineapplication,considertiminganddistancefora
coast-to-stop (Stop Category 0 or Safe Torque Off). For more information on
stop categories and SafeTorque Off, see EN 60204-1 and EN 61800-5-2.

20 Rockwell Automation Publication 750-UM005A-EN-P - October 2018
Chapter 1 About Safe Stop and Safe Monitor Functions
Proof Tests IEC 61508 requires you to perform various proof tests of the equipment that is
used 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 Integrated Safety Functions option module has a useful life of 20 years, no
proof test required. Other components of the system, such as safety I/O
devices, sensors, and actuators can have different useful life times.
PFD and PFH Definitions 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 safety-related 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
order-of-magnitude ranges of its average probability of failure to perform its
safety function on demand or, simply, average probability of 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.
IMPORTANT The time frame for the proof test interval depends on the specific
application.