Rockwell Automation PowerFlex 750 User Manual

PowerFlex 750-Series Safe

Torque Off Option Module

Catalog Number 20-750-S

User Manual

Original Instructions

PowerFlex 750-Series Safe Torque Off Option Module 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.

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).

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	Table of Contents
	Preface
	Summary of Changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. 5
	Conventions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	5
	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) 3 . . . . . . . . .	11
	Proof Tests. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	11
	PFD and PFH Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	12
	Safety 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	Remove Power to the System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	16
	Access the Control Pod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	16
	Set the Safety Enable Jumper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	18
	Install the Safety Option Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	19
	Wire the Safety Option Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	20
	Cabling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	21
	Power Supply Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . .	21
	Verify Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	22
	Chapter 3
Safe Torque Off Option Module	Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	23
Operation	Stop Category Wiring Examples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	24
	Appendix A
Specifications, Certifications, and	Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	31
CE Conformity	Environmental Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	32
	Certifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	33
	CE Conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	34
	Machinery Directive (2006/42/EC) . . . . . . . . . . . . . . . . . . . . . . . .	34
	EMC Directive (2014/30/EU) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	34
	Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	35

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Table of Contents

Notes:

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Preface

Summary of Changes

Conventions

This manual explains how the PowerFlex® 750-Series Safe Torque Off option module can be used in Safety Integrity Level (SIL) 3, 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 Torque Off option module.

Use this manual if you are responsible for designing, installing, configuring, or troubleshooting safety applications that use the PowerFlex 750-Series Safe Torque Off option module.

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.

This manual contains new and updated information as indicated in the following table.

Topic	Page
Updated Important statement in the Set the Safety Enable Jumper section to describe behavior if	18
jumper is not set correctly and list drives which do not have the jumper.
Added Environmental Pollution Degree Description (EN 61800-5-1) table to Appendix A.	32

In this manual, we list configuration parameters by number followed by the name in brackets. For example, P24 [OverSpd Response].

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Preface

Terminology		This table defines abbreviations that are 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 by the 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).
DCavg%	Diagnostic Coverage		Ratio between the failure rate of detected dangerous failures and the failure rate of total dangerous
			failures. (source IEC 61508).
EN	European Norm		The official European Standard.
ESD	Emergency Shutdown Systems		A system, usually independent of the main control system, that is designed to shut down an operating
			system safely.
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 are required 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 that is
			composed of representatives from various national standards organizations.
MTTFD	Mean Time to Failure		The average length of time before a device has a dangerous failure.
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. PELV is defined in IEC 61131-2.
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 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. SELV is defined in IEC 61010-2-201.
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 if there is 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.

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Preface

Additional Resources

These documents contain additional information concerning related Rockwell Automation products.

	Resource	Description
	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,	Information, examples, and techniques that are designed to minimize system failures caused by
	publication GMC-RM001	electrical noise.
	Safety Guidelines for the Application, Installation, and Maintenance of Solid	Describes important differences between solid-state control and hardwired electromechanical
	State Control, publication SGI-1.1	devices.
	Enhanced PowerFlex 7-Class Human Interface Module (HIM) User Manual,	Provides information for using the 20-HIM-A6 Human Interface Module to configure
	publication 20HIM-UM001	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 750-Series Products with TotalFORCE® Control Technical Data,	Provides detailed information on:
	publication 750-TD100	• Drive and bus supply specifications
		•	Option specifications
		• Fuse and circuit breaker ratings
	PowerFlex 750-Series Products with TotalFORCE Control Installation	Provides the basic steps to install PowerFlex 755TL drives, PowerFlex 755TR drives, and
	Instructions, publication 750-IN100	PowerFlex 755TM bus supplies.
	PowerFlex 755TM IP00 Open Type Kits Installation Instructions,	Provides instructions to install IP00 Open Type kits in user-supplied enclosures.
	publication 750-IN101
		Provides detailed information on:
	PowerFlex Drives with TotalFORCE Control Programming Manual,	• I/O, control, and feedback options
	publication 750-PM100	•	Parameters and programming
		• Faults, alarms, and troubleshooting
	PowerFlex 755TM IP00 Open Type Kits Technical Data, publication 750-TD101	Provides detailed information on:
		•	Kit selection
		• Kit ratings and specifications
		•	Option specifications
		Provides detailed information on:
	PowerFlex 750-Series AC Drives Technical Data, publication 750-TD001	• Packaged drive specifications
		• Option specifications
		• Fuse and circuit breaker ratings
	PowerFlex 750-Series AC Drive Installation Instructions, 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.
	Product Certifications website, rok.auto/certifications	Provides declarations of conformity, certificates, and other certification details

You can view or download publications at rok.auto/literature.

Rockwell Automation Publication 750-UM002J-EN-P- February 2021

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Preface

Notes:

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Chapter 1

Safety Concept

Certification

This chapter describes the safety Performance Level concept and how the PowerFlex® 750-Series Safe Torque Off option module meets the requirements for SIL 3, or cat. 3, PLe applications.

Topic	Page
Certification	9
Proof Tests	11
PFD and PFH Definitions	12
Safety Data	12
Safe State	13
Safety Reaction Time	13
Considerations for Safety Ratings	14
Contact Information if Safety Option Failure Occurs	14

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/IEC 61800-5-2, IEC 61508, and SIL CL3 according to 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 deenergized state is considered to be the safe state. The examples in this manual are based on achieving de-energization as the safe state for typical Machine Safety and Emergency Shutdown (ESD) systems.

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Chapter 1

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

•Complete system-level risk assessment and reassess the system any time a change is made

•Certification of the system to the desired safety Performance Level

•Project management and proof testing

•Program 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

IMPORTANT When applying 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.

Safety Category 3 Performance Definition

To achieve Safety Category 3, according to EN ISO 13849-1, design the safetyrelated parts according to these guidelines:

•The safety-related parts of machine control systems and/or their protective equipment, and 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

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Chapter 1

Stop Category Definitions

Conduct a risk assessment to determine the selection of a stop category for each stop function.

•Stop Category 0 is achieved with immediate removal of power to the actuator. This results 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.

IMPORTANT When designing the machine application, consider timing and distance for a coast-to-stop (Stop Category 0 or Safe Torque Off). For more information regarding stop categories and Safe Torque Off, refer to EN 60204-1 and EN/IEC 61800-5-2, respectively.

Performance Level and Safety Integrity Level (SIL) 3

Proof Tests

For safety-related control systems, Performance Level (PL), according to EN 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 EN ISO 13849-1, IEC 61508, and EN 62061 standards for complete information on requirements for PL and SIL determination.

The safety standards require that proof tests be performed on the equipment that is used in the system. Proof tests are performed at user-defined intervals and are dependent upon PFD and PFH values.

IMPORTANT Your specific application determines the time frame for the proof test interval.

Verify operation of safety function after drive installation, modification, or maintenance. See Verify Operation on page 22 for more information.

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Chapter 1

PFD and PFH Definitions

Safety Data

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 that are 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 that are 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 satisfactorily on demand or, simply, average probability of a dangerous failure on demand (PFD). The SIL value for a High Demand/ continuous mode safety-related system is directly related to the average frequency of a dangerous failure occurring per hour (PFH).

PFD and PFH calculations are based on the equations from Part 6 of IEC 61508.

These tables provide data for a 20-year proof test interval and demonstrate the worst-case effect of various configuration changes on the data.

IMPORTANT Determination of safety parameters is based on the assumptions that the system operates in High-demand mode and that the safety function is requested at least once every year.

Table 1 - PFD and PFH for PowerFlex 753 and PowerFlex 755 Drives

		PowerFlex 753 and	PowerFlex 755 Drives	PowerFlex 755 Drives	PowerFlex 755 Drives
	Attribute	PowerFlex 755 Drives
			Frame 8	Frame 9	Frame 10
		Frames 1…7
	PFDavg	3.29E-5	1.73E-4	2.65E-4	3.56E-4
	PFH (1/hour)	3.75E-10	1.99E-9	3.04E-9	4.09E-9
	SIL	3	3	3	3
	PL	e	e	e	e
	Category	3	3	3	3
	MTTFDyears	143	171.9	104.4	75.5
	DCavg%	99 (high)	97.4 (high)	97.5 (high)	97.5 (high)
	HFT	1 (1oo2)	1 (1oo2)	1 (1oo2)	1 (1oo2)
	Mission time	20 years	20 years	20 years	20 years

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