Rockwell Automation Allen-Bradley PowerFlex 7000 Series User manual

PowerFlex 7000 Series
Safe Torque Off
Bulletin Numbers 7000A, 7000, 7000L
User Manual Original Instructions

2Rockwell Automation Publication 7000-UM203D-EN-P - September 2020
PowerFlex 7000 Series Safe Torque Off 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.
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 7000-UM203D-EN-P - September 2020 3
Table of Contents
Preface
About This Publication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Download Firmware, AOP, EDS, and Other Files . . . . . . . . . . . . . . . . . . . . 5
Summary of Changes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Additional Resources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Abbreviations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Chapter 1
General Description What Is the PowerFlex 7000 Drive Safe Torque Off Option? . . . . . . . . . . 7
Safety Standards Applied To Safe Torque Off Option . . . . . . . . . . . . . . . . 8
Chapter 2
Safety Concept Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Safety Certification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Important Safety Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Safety Cat. 3 Performance Definition . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Stop Category Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Performance Level and Safety Integrity Level (SIL) CL3. . . . . . . . . . 10
Functional Proof Tests. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
PFD and PFH Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Safety Parameter Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Safe State . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Safety Reaction Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Considerations for Safety Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Contact Information if Safety Option Failure Occurs . . . . . . . . . . . . . . . 12
Chapter 3
Operation, Installation, and
Wiring
PowerFlex 7000 Drive Safe Torque Off Operation . . . . . . . . . . . . . . . . . . 13
Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Drive Input Isolation Device Interlock . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Product Compatibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Parameter Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Commissioning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Verify Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Chapter 4
System Components STO System Components Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Optical Interface Boards 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Replace Optical Interface Board 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Optical Interface Base Board Safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Replace Optical Interface Base Board Safety. . . . . . . . . . . . . . . . . . . . 28
Optical Interface Base Board Safety Test Points . . . . . . . . . . . . . . . . 29

4Rockwell Automation Publication 7000-UM203D-EN-P - September 2020
Appendix A
Specifications Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
General Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Environmental Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Certifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
CE Conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Machinery Directive (2006/42/EC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
EMC Directive (2014/30/EC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Appendix B
Spare Parts and Preventative
Maintenance
Spare Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Preventative Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Appendix C
History of Changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Rockwell Automation Publication 7000-UM203D-EN-P - September 2020 5
Preface
About This Publication This manual explains how PowerFlex® 7000 drives with Safe Torque Off option
can be used in Safety Integrity Level (SIL) CL3, Performance Level [PLe], or
Category 3 (Cat. 3) applications. It describes the safety requirements, including
PFD and PFH values and application verification information, and provides
information on installing, configuring, and preventative maintenance of the
Safe Torque Off option.
Use this manual if you are responsible for designing, installing, configuring, or
troubleshooting safety applications that use the PowerFlex 7000 drive with
Safe Torque Off option.
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.
Download Firmware, AOP,
EDS, and Other Files
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.
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 Page
Updated standard number that STO satisfies 7
Updated all safety standards applied to STO 8
Updated safety standard number 10
Updated machinery directive standards 32
Updated EMC directive number and standard 32
Updated EU Declaration of Conformity 33
Added History of Changes appendix 37

6Rockwell Automation Publication 7000-UM203D-EN-P - September 2020
Additional Resources These documents contain additional information concerning related products
from Rockwell Automation.
You can view or download publications at rok.auto/literature.
Abbreviations
Resource Description
HMI Interface Board Software Updater and Firmware Download Procedure,
publication 7000-QS002 Provides the procedure to update the HMI board software.
PowerFlex 7000 Medium Voltage AC Drive (Firmware Version 11.xxx) - ForGe
Control, publication 7000-TD002 Provides complete parameter listing for all PowerFlex 7000 medium voltage drives.
PowerFlex 7000 Medium Voltage AC Drive (ForGe Control) - Troubleshooting
Guide, publication 7000-TG002 Provides fault and warning messages, spare parts, and fault and warning codes for all PowerFlex 7000 medium voltage drives.
PowerFlex 7000 Medium Voltage AC Drive (A Frame) - ForGe Control,
publication 7000A-UM200
Provides detailed information on hardware replacement, overview, control and power
component definition, maintenance and specifications for air-cooled medium voltage
variable frequency drives.
PowerFlex 7000 HMI Offering with Enhanced Functionality,
publication 7000-UM201 Provides detailed information to configure, set up, operate, update and troubleshoot the
PowerFlex 7000 HMI Interface Board.
PowerFlex 7000 Medium Voltage AC Drive (B Frame) - ForGe Control,
publication 7000-UM202
Provides detailed information on hardware replacement, overview, control and power
component definition, maintenance and specifications for air-cooled medium voltage
variable frequency drives.
PowerFlex 7000 Medium Voltage AC Drive (C Frame) - ForGe Control,
publication 7000L-UM301
Provides detailed information on hardware replacement, overview, control and power
component definition, maintenance and specifications for liquid-cooled medium voltage
variable frequency drives.
EtherNet/IP Network Devices User Manual, ENET-UM006 Describes how to configure and use EtherNet/IP devices to communicate on the EtherNet/IP
network.
Ethernet Reference Manual, ENET-RM002 Describes basic Ethernet concepts, infrastructure components, and infrastructure features.
System Security Design Guidelines Reference Manual, SECURE-RM001 Provides guidance on how to conduct security assessments, implement Rockwell Automation products in a secure system, harden the control system, manage user access,
and dispose of equipment.
Industrial Components Preventive Maintenance, Enclosures, and Contact
Ratings Specifications, publication IC-TD002 Provides a quick reference tool for Allen-Bradley industrial automation controls and
assemblies.
Safety Guidelines for the Application, Installation, and Maintenance of
Solid-state Control, publication SGI-1.1
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.
Industrial Automation Wiring and Grounding Guidelines, publication 1770-4.1 Provides general guidelines for installing a Rockwell Automation industrial system.
Product Certifications website, rok.auto/certifications. Provides declarations of conformity, certificates, and other certification details.
Abbreviation Description
DCavg Diagnostic Coverage (Average)
DIC Drive Input Contactor
DPM Drive Processor Module
ForGe Fourth Generation Control
MTTFdMean Time to Dangerous Failure
OIB2 Optical Interface Board (Rev. 2)
OIBBS Optical Interface Base Board Safety
PFD Probability of Failure on Demand
PFH Probability of a Dangerous Failure occurring per
Hour
PSD Power Structure Diagnostic
PWM Pulse Width Modulation
SCR Silicon Controlled Rectifier
SGCT Symmetrical Gate Commutated Thyristor
SPS Self-powered SGCT (Power Supply)
STO Safe Torque Off
STORK Safe Torque Off Retrofit

Rockwell Automation Publication 7000-UM203D-EN-P - September 2020 7
Chapter 1
General Description
The Safe Torque Off option is intended to be applied as a component in a
safety control system. Components in the system must be chosen and applied
appropriately to achieve the desired level of operational safety.
What Is the PowerFlex 7000
Drive Safe Torque Off
Option?
The PowerFlex™ 7000 Drive Safe Torque Off option:
• Is designed to help safely remove power from the gate firing circuits of
the drive’s power devices (SGCTs). This helps prevent the drive’s power
devices from switching in the pattern necessary to generate AC power to
the motor.
• Satisfies the STO definition in IEC 61800-5-2:2016.
• 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
Cat. 3 for Safe Torque Off (STO).
IMPORTANT This option is suitable for performing mechanical work on the
drive system or affected area of a machine only. It does not
provide electrical safety.
This option should not be used as a control for starting and/or
stopping the drive.
ATTENTION: Electrical Shock Hazard. Verify that all sources of AC and DC
power are de-energized and locked out or tagged out in accordance with the
requirements of ANSI/NFPA 70E, Part II.
ATTENTION: In safe-off mode, hazardous voltages may still be present at
the motor. To avoid an electric shock hazard, disconnect power to the motor
and verify that the voltage is zero before performing any work on the motor.
ATTENTION: There is a residual risk associated with four or more failures of
SCGTs within the drive that would cause torque to be developed even when
the PowerFlex 7000 Drive Safe Torque Option has controlled the drive
outputs to the off state. In this case, the drive may provide energy until the
published response time of 1000 ms has expired.
ATTENTION: Removal of power generation from the drive to the motor does
not ensure the motor will not rotate. Mechanical braking may be necessary
in order to prevent motor rotation. In the absence of motor braking, the
motor may continue to rotate or may start to rotate based on the inertia of
the load, stored energy in the load, or external forces.

8Rockwell Automation Publication 7000-UM203D-EN-P - September 2020
Chapter 1 General Description
Safety Standards Applied
To Safe Torque Off Option
The Safe Torque Off option satisfies applicable requirements in the following
standards related to functional and machinery safety.
• IEC 61508-1 to 7: 2010
• IEC 61800-5-2:2016
• IEC 61800-3:2017
• IEC 61800-5-1:2007 + A1:2016
• IEC 62061:2005 + A1:2012 + A2:2015
• ISO 13849-1:2015
• IEC 60204-1:2016
• EN 60204-11: 2000

Rockwell Automation Publication 7000-UM203D-EN-P - September 2020 9
Chapter 2
Safety Concept
Introduction This section describes the safety performance level concept and how the
PowerFlex™ 7000 drives can meet the requirements for SIL CL3, Cat. 3, or PLe
applications.
Safety Certification The PowerFlex 7000 drive safety option is certified for use in safety
applications up to and including SIL 3 according to IEC 61800-5-2, IEC 61508,
and IEC 62061, PLe, and Cat. 3 according to ISO 13849-1. Safety requirements
are based on the standards current at the time of certification.
The TÜV Rheinland group has approved the PowerFlex 7000 drive safety
option 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.
Important Safety Considerations
The system user is responsible for:
• the 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
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.
IMPORTANT When applying Functional Safety, restrict access to qualified,
authorized personnel who are trained and experienced.
IMPORTANT This safety function may be used where power removal is
required to prevent unexpected start-up.
ATTENTION: The drive should never be considered in a safe state unless the
safety function is active.

10 Rockwell Automation Publication 7000-UM203D-EN-P - September 2020
Chapter 2 Safety Concept
Safety Cat. 3 Performance Definition
To achieve Safety Cat. 3 according to ISO 13849-1:2015, the safety-related parts
have to be designed such that:
• 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.
Stop Category Definitions
The selection of a stop category for each stop function must be determined by a
risk assessment.
• Stop Category 0 is achieved with immediate removal of power to the
actuator, resulting in an uncontrolled coast to stop. Safe Torque Off
accomplishes a Stop Category 0 stop.
• Stop Category 1 is achieved with power available to the machine
actuators to achieve the stop. Power is removed from the actuators when
the stop is achieved.
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 IEC 62061, include a rating
of the system’s ability to perform its safety functions. All of the safety-related
components of the control system must be included in both a risk assessment
and the determination of the achieved levels.
Refer to the ISO 13849-1, IEC 61508, and IEC 62061 standards for complete
information on requirements for PL and SIL determination.
ATTENTION: When designing your system, consider how personnel will exit
the machine if the door locks while they are in the machine. Additional
safeguarding devices may be required for your specific application.
IMPORTANT When designing the machine application, timing and distance
should be considered for a coast to stop (Stop Category 0 or Safe
Torque Off). For more information regarding stop categories,
refer to IEC 60204-1.