Rockwell Automation Allen-Bradley PowerFlex 750 Series User manual

PowerFlex 750-Series Safe Torque Off Option Module
Catalog Number 20-750-S
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 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.
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).

Rockwell Automation Publication 750-UM002H-EN-P - February 2017 3
Table of Contents
Preface
Summary of Changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Conventions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Terminology. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Additional Resources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Chapter 1
Safety Concept Certification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Important Safety Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Safety Category 3 Performance Definition. . . . . . . . . . . . . . . . . . . 10
Stop Category Definitions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Performance Level and Safety Integrity Level (SIL) CL3 . . . . . . 11
Functional Proof Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
PFD and PFH Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
PFD and PFH Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Safe State . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Safety Reaction Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Considerations for Safety Ratings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Contact Information if Safety Option Failure Occurs . . . . . . . . . . . . 14
Chapter 2
Installation and Wiring Access the Drive Control Pod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Set the Safety Enable Jumper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Remove Power From the Drive System. . . . . . . . . . . . . . . . . . . . . . . . . . 21
Verify Zero Voltage on PowerFlex 755 and
PowerFlex 753 Drives. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Verify Zero Voltage on PowerFlex 755T Drive Products . . . . . . 22
Install the Safety Option Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Wire the Safety Option Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Cabling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Power Supply Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Port Assignment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Jumper Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Verify Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Chapter 3
Safe Torque Off Option Module
Operation
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Stop Category Wiring Examples. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

4Rockwell Automation Publication 750-UM002H-EN-P - February 2017
Table of Contents
Appendix A
Specifications,Certifications, and
CE Conformity
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Environmental Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Certifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
CE Conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Machinery Directive (2006/42/EC) . . . . . . . . . . . . . . . . . . . . . . . . 38
EMC Directive (2004/108/EC and 2014/30/EU) . . . . . . . . . . . 38

Rockwell Automation Publication 750-UM002H-EN-P - February 2017 5
Preface
This manual explains how PowerFlex® 750-Series Safe Torque Off option
module can be used in Safety Integrity Level (SIL) CL3, Performance Level
[PLe], or Category (CAT.) 3 applications. It describes the safety requirements,
including PFD and PFH values and application verification information, and
provides information on installing, configuring, and troubleshooting the Safe
To r q u e O f f o p t i o n m o d u l e .
Use this manual if you are responsible for designing, installing, configuring, or
troubleshooting safety applications that use the PowerFlex 750-Series Safe
To r q u e O f f o p t i o n m o d u l e .
The 20-750-S Safe Torque Off option module applies to the following
PowerFlex 750-Series drives:
• PowerFlex 755TL low-harmonic, non-regenerative drives
• PowerFlex 755TR regenerative drives
• PowerFlex 755TM drive systems with regenerative bus-supplies and
common-bus inverters
• PowerFlex 755 AC drives
• PowerFlex 753 AC drives
Throughout this manual, PowerFlex 755T drive products is used to refer to
PowerFlex 755TL drives, PowerFlex 755TR drives, and PowerFlex 755TM
drive systems.
We recommend that you have a basic understanding of the electrical circuitry
and familiarity with these products. You must also be trained and experienced
in the creation, operation, and maintenance of safety systems.
Summary of Changes This manual contains new and updated information as indicated in the
following table.
Topic Page
Added safety specifications (including PFD andPFH values) for PowerFlex 755T drive products. 12
Updated the Safe State information and added Safety Reaction Time specifications for PowerFlex
755T drive products. 13
UpdatedAccess the Drive Control Pod with references to PowerFlex 755T drive products. 16…19
Updated jumper setting figures and added figure for PowerFlex 755T drive products. 20…21
Added Remove Power From the Drive System. 21
Updated Stop Category Wiring Examples with Guardmaster® safety relays. 30…33
Added Stop Category Wiring Example with POINT Guard I/O™ modules. 34
Updated Environmental Specifications table. 36

6Rockwell Automation Publication 750-UM002H-EN-P - February 2017
Preface
Conventions In this manual, configuration parameters are listed by number followed by the
name in brackets. For example, P24 [OverSpd Response].
Terminology This table defines abbreviations used in this manual.
Abbreviation Full Term Definition
1oo2 One out of Two Refers to the behavioral design of 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 EN ISO 13849-1).
CL Claim Limit The maximum SIL rating that can be claimed for a Safety-Related Electrical Control System subsystem
in relation to architectural constraints and systematic safety integrity (source IEC 62061).
EN European Norm The official European Standard.
ESD Emergency Shutdown Systems A system, usually independent of the main control system, that is designed to safely shut down an
operating system.
HFT Hardware Fault Tolerance The HFT equals n, where n+1 faults could cause the loss of the safety function. An HFT of 1 means that
2 faults arerequired before safety is lost.
HIM Human Interface Module A module used to configure a device.
IEC International Electrotechnical Commission The International Electrotechnical Commission (IEC) is the world’s leading organization that prepares
and publishes International Standards for all electrical, electronic and related technologies.
IGBT Insulated Gate Bi-polar Transistors Typical power switch used to control main current.
ISO International Organization for Standardization The International Organization for Standardization is an international standard-setting body
composed of representatives from various national standards organizations.
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.
PFD Probability of Dangerous Failure on Demand The average probability of a system to fail to perform its design function on demand.
PFH Probability of Dangerous Failure per Hour The probability of a system to have a dangerous failure occur per hour.
PL Performance Level EN ISO 13849-1 safety rating
SELV Safety Extra Low Voltage Circuit A secondary circuit that is designed and protected so that, under normal and single fault conditions, its
voltages do not exceed a safe value.
SIL Safety Integrity Level A measure of a products ability to lower the risk that a dangerous failure could occur.
STO Safe Torque Off The Safe Torque Off (STO) function is used to prevent unexpected motor rotation in the event of an
emergency while the drive remains connected to the power supply. When STO is activated, the torque
power cannot reach the drive, thus stopping and preventing any motor shaft rotation.

Rockwell Automation Publication 750-UM002H-EN-P - February 2017 7
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 Technical Data,
publication 750-TD100 Provides detailed information on: • Drive and bus supply specifications
• Option specifications
• Fuse and circuit breaker ratings
PowerFlex 755TM IP00 Open Type Kits Technical Data, publication 750-TD101 Provides detailed information on:
• Kit selection
• Kit ratings and specifications
• Option specifications
PowerFlex 750-Series Products with TotalFORCE™ Control Installation
Instructions, publication 750-IN100
Provides the basic steps to install PowerFlex 755TL drives, PowerFlex 755TR drives, and
PowerFlex 755TM bus supplies.
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 InstallationInstructions, publication 750-IN001
Provides information on installing the Safe Torque OFF option module in PowerFlex 750-Series
drive.
PowerFlex 750-Series AC Drives Programming Manual, publication
750-PM001 Provides information on mounting, installing, and configuring 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.
Connected Components Workbench Online Help Online Help that provides a description of the different elements of the Connected Components
Workbench™ software.
PowerFlex Safe Speed Monitor Safety Reference Manual, publication
750-RM001
Provides information on installing and configuring the Safe Speed Monitor option module with
PowerFlex 750-Series drives.
System Design for Control of Electrical Noise Reference Manual,
publication GMC-RM001 Information, examples, and techniques designed to minimize system 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.

8Rockwell Automation Publication 750-UM002H-EN-P - February 2017
Preface
Notes:

Rockwell Automation Publication 750-UM002H-EN-P - February 2017 9
Chapter 1
Safety Concept
This chapter describes the safety performance level concept and how the
PowerFlex® 750-Series Safe Torque Off option module meets the requirements
for SIL CL3, CAT. 3, or PLe applications.
Certification The PowerFlex 750-Series Safe Torque Off option module is certified for use in
safety applications up to and including SIL 3 according to EN 61800-5-2, IEC
61508, and EN 62061, Performance Level PLe and Category 3 according to
EN ISO 13849-1. Safety requirements are based on the standards current at
the time of certification.
The TÜV Rheinland group has approved the PowerFlex 750-Series Safe
Torque Off option module for use in safety-related applications where the de-
energized state is considered to be the safe state. All of the examples in this
manual are based on achieving de-energization as the safe state for typical
Machine Safety and Emergency Shutdown (ESD) systems.
Topic Page
Certification 9
Functional Proof Tests 11
PFD and PFH Definitions 12
PFD and PFH Data 12
Safe State 13
Safety Reaction Time 13
Considerations for Safety Ratings 14
Contact Information if Safety Option Failure Occurs 14

10 Rockwell Automation Publication 750-UM002H-EN-P - February 2017
Chapter 1 Safety Concept
Important Safety Considerations
The system user is responsible for the following:
• Set-up, safety rating, and validation of any sensors or actuators
connected to the system
• Completing a system-level risk assessment and reassessing the system any
time a change is made
• Certification of the system to the desired safety performance 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
• Analyzing all configuration settings and choosing the proper setting to
achieve the required safety rating
Safety Category 3 Performance Definition
To achieve Safety Category 3, according to EN ISO 13849-1, design the safety-
related parts according to these guidelines:
• The safety-related parts of machine control systems and/or their
protective equipment, as well as their components, shall be designed,
constructed, selected, assembled, and combined in accordance with
relevant standards so that they can withstand expected conditions
• Basic safety principles shall be applied
• A single fault in any of its parts does not lead to a loss of safety function.
• The average diagnostic coverage of the safety-related parts of the control
system shall be medium
• The mean-time to dangerous failure of each of the redundant channels
shall be high
• Measures against common cause failure shall be applied
IMPORTANT When applying Functional Safety, restrict access to qualified, authorized
personnel who are trained and experienced.
ATTENTION: When designing your system, consider how personnel exit the
machine if the door locks while they are in the machine. Additional
safeguarding devices may be required for your specific application.