Rockwell Automation Allen-Bradley PowerFlex 750 Series Bedienungsanleitung

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-UM002I-EN-P - August 2019 3

Table of Contents

Preface

Summary of Changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Conventions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Terminology. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Additional Resources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Chapter 3

Safe Torque Off Option Module

Operation

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Stop Category Wiring Examples. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Appendix A

Specifications, Certifications, and

CE Conformity

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Environmental Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Certifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

CE Conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Machinery Directive (2006/42/EC) . . . . . . . . . . . . . . . . . . . . . . . . 34

EMC Directive (2014/30/EU) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Index

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

4Rockwell Automation Publication 750-UM002I-EN-P - August 2019

Table of Contents

Notes:

Rockwell Automation Publication 750-UM002I-EN-P - August 2019 5

Preface

This manual explains how 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

To r q u e O ff op 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 definitions for DCavg%, and MTTFD to the Terminology table. 6

Updated the definitions of PELV, PFH, and SELV in theTerminology table. 6

Added the PowerFlex 750-Series AC Drives Technical Data publication to the Additional Resources

table. 8

Updated the definition of PFH in PFD and PFH Definitions section. 12

Changed the PFD and PFH data section to Safety Data section. 12

Added IMPORTANT statement to Safety Data section for determination of safety parameters. 12

Added rows for MTTFDyears and DCavg% data to PFD and PFH for PowerFlex 753 and PowerFlex

755 Drives table and PFD and PFH for PowerFlex 755T Drive Products table. 12, 13

Added columns for Drive Frames 5 and 6, Drive Frames 7 and 8, Drive Frame 13, Drive Frame 14,

and Drive Frame 15 to PFD and PFH for PowerFlex 755T Drive Products table. 13

Updated the list of supported drive families in the Safety Reaction Time table. 13

Updated the Remove Power to the System section in the Installation and Wiring chapter. 16

6Rockwell Automation Publication 750-UM002I-EN-P - August 2019

Preface

Conventions In this manual, we list configuration parameters by number followed by the

name in brackets. For example, P24 [OverSpd Response].

Terminology This table defines abbreviations that are used in this manual.

Updated the Access the Control Pod section. 16

Updated the Set the Safety Enable Jumper section - mentioned Safety Jumper In fault (F213). 18

Added an Important note to the Install the Safety Option Module section. 19

Added parameter 10:351 [M Start Inhibits] for the PowerFlex 755T to the Operation section. 23

Updated the drive families examples in Stop Category Wiring Examples section. 24

Updated Standards and Safety Categories in the General Specifications table to show card

certifications when used with the PowerFlex 750-Series and when used with the

PowerFlex 750-Series with TotalFORCE Control.

Updated Certifications table to show latest Directive number. 33

Topic Page

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.

MTTFDMean 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

Rockwell Automation Publication 750-UM002I-EN-P- August 2019 7

Preface

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.

Abbreviation Full Term Definition

8Rockwell Automation Publication 750-UM002I-EN-P - August 2019

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 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 that are 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.

Enhanced PowerFlex 7-Class Human Interface Module (HIM) User Manual,

publication

20HIM-UM001

Provides information for using the 20-HIM-A6 Human Interface 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 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 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 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 AC Drives Technical Data, publication 750-TD001

Provides detailed information on:

• 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

Rockwell Automation Publication 750-UM002I-EN-P - August 2019 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 3, or cat. 3, 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/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 de-

energized 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.

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

10 Rockwell Automation Publication 750-UM002I-EN-P - August 2019

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

• 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

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, 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

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.

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