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PowerFlex 755 Integarated Safety - Safe Torque Off Option Module User Manual

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PowerFlex 755 Integrated Safety - Safe Torque Off Option ModuleCatalog Number 20-750-S3User ManualOriginal InstructionsImportant User InformationRead 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 prohibitedThroughout 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.IMPORTANTIdentifies 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-UM004A-EN-P - February 20173Table of ContentsPreface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7Conventions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Terminology. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9Product Firmware and Release Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . 10Additional Resources. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11Chapter 1Safety ConceptWhat Is the Integrated Safety - Safe Torque Off Option Module? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13Compatible Drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14Compatible Safety Controllers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14Network Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14Hardwired Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15Safety Application Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15Safety Standards Applied to the Integrated Safety - Safe Torque Off Option Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15Safety Certification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15Important Safety Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . 16Stop Category Definitions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16Performance Level and Safety Integrity Level (SIL) CL3 . . . . . . 17Functional Proof Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17PFD and PFH Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17PFD and PFH Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18Safety Reaction Time. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18Considerations for Safety Ratings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19Contact Information If Safety Option Failure Occurs . . . . . . . . . . . . 19Chapter 2InstallationRemove Power from the Drive System . . . . . . . . . . . . . . . . . . . . . . . . . . 22Verify Zero Voltage on PowerFlex 755 Drives. . . . . . . . . . . . . . . . 22Verify Zero Voltage on PowerFlex 755T Drive Products. . . . . . 22Access the Drive Control Pod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25Set the Safety Jumper. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29Install the Safety Option Module. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30Chapter 3ConfigurationDescription of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31Out-of-Box State. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32Recognize Out-of-Box State . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32Restore the Drive to Out-of-Box State. . . . . . . . . . . . . . . . . . . . . . . 324Rockwell Automation Publication 750-UM004A-EN-P - February 2017Table of ContentsChapter 4Network STO Programming and OperationDescription of Integrated Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . 35Safe Torque Off Assembly Tags . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36Configure Safe Torque Off for a PowerFlex 755 Drive in the Studio 5000 Logix Designer Application . . . . . . . . . . . . . . . . . . . . . . . . 37Add a 20-750-S3 Peripheral Device to a PowerFlex 755 Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38Configure the Safety Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . 39Generate the Safety Network Number (SNN) . . . . . . . . . . . . . . . 41Safety Tab Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42Safety Configuration Signature and Ownership . . . . . . . . . . . . . . 44Reset Ownership . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44Safe Torque Off – Stop Category 0 Example Program. . . . . . . . . . . . 45Safe Torque Off – Stop Category 1 Example Program. . . . . . . . . . . . 46Falling Edge Reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47Safety Tags in Standard Routines . . . . . . . . . . . . . . . . . . . . . . . . . . . 47Standard Tags in Safety Routines (tag mapping). . . . . . . . . . . . . . 47Safe Torque Off Fault Reset. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48Understand Integrated Safety Drive Replacement. . . . . . . . . . . . . . . . 50Replace an Integrated Safety Drive in a GuardLogix System. . . . . . . 50Chapter 5Hardwired STO Wiring and OperationWiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53Cabling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54Power Supply Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54Description of Hardwired Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . 55Selection of Hardwired Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55Configure the Drive with Hardwired Safety Connections . . . . . . . . 55Timing Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56Chapter 6Monitoring and TroubleshootingMonitor STO Status By Using the Module LEDs. . . . . . . . . . . . . . . . 59Module Status LED (DS1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59Network Status LED (DS2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60Motion Output Status LED (DS3) . . . . . . . . . . . . . . . . . . . . . . . . . 60Monitor STO With a HIM or Software. . . . . . . . . . . . . . . . . . . . . . . . . 61Fault Messages on HIM, Drive AOP, and Connected Components Workbench Software . . . . . . . . . . . . . . 61Safety Supervisor State . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64Safe Torque Off Faults. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64Rockwell Automation Publication 750-UM004A-EN-P - February 20175Table of ContentsAppendix ASpecifications, Certifications, and CE ConformityIntegrated Safety - Safe Torque Off Option Module Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65Environmental Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66Certifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67CE Conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67Machinery Directive (2006/42/EC) . . . . . . . . . . . . . . . . . . . . . . . . 67EMC Directive (2014/30/EU) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68Waste Electrical and Electronic Equipment (WEEE) . . . . . . . . . 68Appendix BSTO Option Module Replacement ConsiderationsInstallation Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69Option Module Slots . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70Safe Torque Off Option Module. . . . . . . . . . . . . . . . . . . . . . . . . . . . 70Integrated Safety - Safe Torque Off Option Module. . . . . . . . . . 70Appendix CParameter DataParameters and Settings in a Linear List . . . . . . . . . . . . . . . . . . . . . . . . . 71Device Config Parameters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71Host Config Parameters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

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