Allen-Bradley PowerFlex 755 User manual

PowerFlex 755/755T Integrated Safety Functions

Option Module

Catalog Number 20-750-S4

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 aboutpractices 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 iscritical 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.

BURNHAZARD: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

potentialArcFlash.ArcFlashwillcausesevereinjury or death. WearproperPersonalProtectiveEquipment(PPE).FollowALL

Regulatory requirements for safe work practices and for Personal Protective Equipment (PPE).

Rockwell Automation Publication 750-UM005A-EN-P - October 2018 3

TableofContents

Preface

Conventions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Terminology. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Product Firmware and Release Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Additional Resources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Chapter 1

AboutSafeStopandSafeMonitor

Functions What Is the Integrated Safety Functions Option Module? . . . . . . . . 15

Compatible Drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Compatible Safety Controllers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Safety Application Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Safety Certification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Important Safety Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Stop Category Definitions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Performance Level and Safety Integrity Level (SIL) CL3 . . . . . . 19

Proof Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

PFD and PFH Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

PFD and PFH Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Safety Data for Safe Torque Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Safety Data for Safe Feedback. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Safety Data for Safety I/O. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Spurious Trip Rate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Safety Reaction Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Considerations for Safety Ratings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Encoder Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Supported Encoders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Encoder Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

General Encoder Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Digital AqB Diagnostics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Sine/Cosine and Hiperface Diagnostics . . . . . . . . . . . . . . . . . . . . . 27

Contact Information If Safety Option Failure Occurs . . . . . . . . . . . . 29

Chapter 2

Installation Remove Power to the System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Access the Control Pod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Set the SAFETY and Hardware ENABLE Jumpers . . . . . . . . . . . . . . 33

Install the Safety Option Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Feedback Installation Guidelines. . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

I/O Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Cabling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Power Supply Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

4Rockwell Automation Publication 750-UM005A-EN-P - October 2018

Table of Contents

Chapter 3

Safety I/O Safety Inputs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Safety Input Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Latch Input Error Operation in Single Channel Mode. . . . . . . . 41

Single Channel Safety Input Status Data. . . . . . . . . . . . . . . . . . . . . 42

Dual-channel Safety Input Operation . . . . . . . . . . . . . . . . . . . . . . . 43

Equivalent Dual-channel Input Operation. . . . . . . . . . . . . . . . . . . 44

Complementary Dual-channel Input Operation . . . . . . . . . . . . . 45

Standard Input Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Safety Input Safety Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Safety Input Alarms. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

Determining Safety Input Alarm Type . . . . . . . . . . . . . . . . . . . . . . 50

Safety Input Alarm Recovery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

Input Delays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

Use With PowerFlex 750-Series ATEX Option Module . . . . . . 52

Safety Outputs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

Safety Output with Test Pulse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

Single-channel Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

Latch Output Error Operation in Single Channel Mode . . . . . . 54

Dual-channel Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

Latch Output Error Operation in Dual Channel Mode . . . . . . . 55

Safety Output Safety Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

Commanding Safety and Test Outputs. . . . . . . . . . . . . . . . . . . . . . 59

Safety Output Alarms. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

Determining Safety Output Alarm Type . . . . . . . . . . . . . . . . . . . . 61

Safety Output Alarm Recovery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

Test Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

Standard Output Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

Test Output Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

Power Supply Output. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

Test Output Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

Test Output Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

Test Output Ready . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

Chapter 4

Drive-based Safe Stop Functions Safety Output Assembly Safe Stop Function Tags. . . . . . . . . . . . . . . . 67

Safety Input Assembly Safe Stop Function Tags. . . . . . . . . . . . . . . . . . 68

Safety Function in Response to Connection Event . . . . . . . . . . . . . . . 70

Connection Loss Action . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

Connection Idle Action. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

Safe Torque Off Function. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

Safe Torque Off Activation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

Safe Torque Off Reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

Safe Torque Off Delay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

Safe Torque Off Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

Safe Torque Off Stopping Action and Source . . . . . . . . . . . . . . . . 76

Rockwell Automation Publication 750-UM005A-EN-P - October 2018 5

Table of Contents

STO Safety Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

Safe Stop 1 Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

Safe Stop 1 Activation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

Safe Stop 1 Reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

Safe Stop 1 Stopping Action and Source . . . . . . . . . . . . . . . . . . . . . 80

Timed Safe Stop 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

Monitored Safe Stop 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

SS1 Safety Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84

Safe Brake Control Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

Safe Brake Control Activation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

Safe Brake Control Reset. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86

Safe Brake Control Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

Safe Brake Control Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88

SBC Safety Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93

Connecting a Safety Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93

Chapter 5

Controller-based Safety

Functions Drive Safety Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95

Before Adding the Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . 97

Drive Safety Instruction Example . . . . . . . . . . . . . . . . . . . . . . . . . . . 97

Pass-through Data Using Standard I/O Mode . . . . . . . . . . . . . . . . . . . 98

Pass-through Data Using Integrated Motion. . . . . . . . . . . . . . . . . . . . 100

SFX Instruction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101

SFX Instruction Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102

Chapter 6

Standard I/O Mode –

Configuration, Programming,

and Operation

Safety Assembly Tags . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105

Configure Safety in the Logix Designer Application . . . . . . . . . . . . . 106

Add a PowerFlex 755 Drive/755T Drive Product to the

Safety Controller Project. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106

Add an Option Module to a PowerFlex 755 Drive. . . . . . . . . . . 108

Generate the Safety Network Number (SNN) . . . . . . . . . . . . . . 110

Safety Configuration Signature and Ownership . . . . . . . . . . . . . 125

Reset Ownership . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126

Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126

Safety Tags in Standard Routines . . . . . . . . . . . . . . . . . . . . . . . . . . 126

Standard Tags in Safety Routines (tag mapping). . . . . . . . . . . . . 126

Standard and Safety Tasks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127

Safety Function Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127

Pass-through Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129

Falling Edge Reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129

Understand Integrated Safety Drive Replacement. . . . . . . . . . . . . . . 129

Replace an Integrated Safety Drive in a GuardLogix System . . 130

PowerFlex 755 IO Mode Using SFX, SS1, and SLS Instructions. . 132

Studio 5000 Logix Designer Application Configuration . . . . . 132

Programming Example. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135

6Rockwell Automation Publication 750-UM005A-EN-P - October 2018

Table of Contents

Chapter 7

Integrated Motion –

Configuration, Programming,

and Operation

Safety Assembly Tags . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143

Configure the Integrated Safety Function Option Module in the

Logix Designer Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144

Add a PowerFlex 755 Drive to the Controller Project. . . . . . . . 144

Understand Module Properties Categories . . . . . . . . . . . . . . . . . . . . . 145

Module Properties>General Category. . . . . . . . . . . . . . . . . . . . . . 146

Module Properties>Connection and Safety Categories . . . . . . 149

Motion Safety>Actions Category . . . . . . . . . . . . . . . . . . . . . . . . . . 152

Motion Safety>Primary Feedback Category . . . . . . . . . . . . . . . . 153

Motion Safety>Secondary Feedback Category . . . . . . . . . . . . . . 155

Motion Safety>Scaling Category. . . . . . . . . . . . . . . . . . . . . . . . . . . 156

Motion Safety>Discrepancy Checking Category . . . . . . . . . . . . 157

Motion Safety>STO Category. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158

Motion Safety>SS1 Category. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159

Motion Safety>SBC Category . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160

Motion Safety>Input Configuration Category. . . . . . . . . . . . . . 161

Motion Safety>Test Output Category . . . . . . . . . . . . . . . . . . . . . 162

Motion Safety>Output Configuration Category . . . . . . . . . . . . 163

Axis Properties > Actions > Safety Actions . . . . . . . . . . . . . . . . . 164

Module Properties > Associated Axes Motor and Load

Feedback Device. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165

Generate the Safety Network Number (SNN) . . . . . . . . . . . . . . 166

Safety Configuration Signature and Ownership . . . . . . . . . . . . . 167

Reset Ownership . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168

Replace an Integrated Safety Drive in a GuardLogix System . . 168

Motion Direct Commands in Motion Control Systems. . . . . . 169

Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176

Motion and Safety Tasks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176

Motion Safety Instances. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176

Safety Function Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176

Safe Monitor Network Communication. . . . . . . . . . . . . . . . . . . . 179

Explicit Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183

Application Example - Using SFX, SS1, and SLS Instructions

with Integrated Motion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184

Studio 5000 Logix Designer Application Configuration . . . . . 185

Programming Example. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187

Chapter 8

Monitoring and Troubleshooting Monitor Status Using Status Indicators . . . . . . . . . . . . . . . . . . . . . . . . 195

Module Status Indicator (DS1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196

Network Status Indicator (DS2). . . . . . . . . . . . . . . . . . . . . . . . . . . 196

Motion Output Status Indicator (DS3) . . . . . . . . . . . . . . . . . . . . 197

Safety Fault Indicator (DS4). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197

Safety Fault Names . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197

Understand Safety Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199

Rockwell Automation Publication 750-UM005A-EN-P - October 2018 7

Table of Contents

Safety Supervisor State . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199

Safety Core Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199

Safe Torque Off Fault. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200

Safe Stop 1 Fault. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201

Safe Brake Control Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202

SS2, SOS, SLS, SLP, and SDI Faults. . . . . . . . . . . . . . . . . . . . . . . . 202

Safety Feedback Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203

Safety Fault Reset. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204

Monitor Status with a HIM or Software. . . . . . . . . . . . . . . . . . . . . . . . 205

Fault Messages on HIM, Drive Module, and Connected

Components Workbench Software . . . . . . . . . . . . . . . . . . . . . . . . 205

Monitor Status Using Integrated Motion . . . . . . . . . . . . . . . . . . . . . . 210

Out-of-Box State. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214

Recognize Out-of-Box State . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214

Restore the Drive to Out-of-Box State. . . . . . . . . . . . . . . . . . . . . . 214

Appendix A

Safety Function Validation

Checklist Safe Stop 1 (SS1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218

Safe Stop 2 (SS2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220

Safe Operating Speed (SOS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223

Safely-limited Speed (SLS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225

Safely-limited Position (SLP). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226

Safe Direction (SDI) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228

Safe Feedback Interface (SFX). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229

Safe Brake Control (SBC). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231

Appendix B

Specifications,Certifications,and

CE Conformity Integrated Safety Functions Option Module Specifications . . . . . . 233

Electrical Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234

Environmental Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235

Certifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236

CE Conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236

Machinery Directive (2006/42/EC) . . . . . . . . . . . . . . . . . . . . . . . 236

EMC Directive (2014/30/EU) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237

Waste Electrical and Electronic Equipment (WEEE) . . . . . . . . 237

Appendix C

Safety I/O Assemblies and Safety

Attributes Safety Assembly Tags . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240

Safety Feedback Attributes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245

Safe Stop Function Attributes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 247

Explicit Messages. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 251

Example: Read SS1 Fault Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . 251

8Rockwell Automation Publication 750-UM005A-EN-P - October 2018

Table of Contents

Appendix D

Parameter Data Parameters and Settings in a Linear List . . . . . . . . . . . . . . . . . . . . . . . . 253

Device Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 253

Host Config Parameters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 259

Index

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 263

Rockwell Automation Publication 750-UM005A-EN-P - October 2018 9

Preface

This user manual explains how to use PowerFlex® 755 drives and PowerFlex

755T drive products in safety applications up to safety integrity level 3 (SIL 3),

performance level e (PLe), category 4.

This user manual is intended for people that design, install, configure, or

troubleshoot safety applications that use the Integrated Safety Functions

option module (catalog number 20-750-S4).

This user manual covers using network safety with drives in Standard I/O

mode and Integrated Motion mode. All chapters apply to both modes with the

following exceptions:

•Chapter 6 is specific to Standard I/O mode and can be skipped if you are

using Integrated Motion mode.

•Chapter 7 is specific to Integrated Motion mode and can be skipped if

you are using Standard I/O mode.

This user manual describes the safety requirements, including probability of

dangerous failure on demand (PFD) and average frequency of a dangerous

failure (PFH) per hour values and application verification information (see

PFD and PFH Data on page 21).

Conventions This manual lists identifies parameter names by listing the parameter number

first, followed by the name in brackets. For example, P7 [STO Fault Type].

Both the Host Config and Device Config parameters exist for this option

module and the parameter numbers overlap. For example, there is a P3 [Device

Config Identity State] and a P3 [Host Config Safety State]. Host Config

parameters reside on the Host (that is, the drive) side of the option module and

are specific to supporting the option module. Device Config parameters reside

on the option module itself.

Throughout this manual, the PowerFlex 755/755T Integrated Safety

Functions option module is also referred to as the Integrated Safety Functions

option module.

Topic Page

Conventions 9

Terminology 10

Product Firmware and Release Notes 12

Additional Resources 13

IMPORTANT You must have a basic understanding of electrical circuitry and familiarity

withPowerFlex755 drivesand PowerFlex755Tdriveproducts. You mustalso

be trained and experienced in the creation, operation, and maintenance of

safety systems.

10 Rockwell Automation Publication 750-UM005A-EN-P - October 2018

Preface

Throughout this manual, the PowerFlex 755TL low harmonic drives,

PowerFlex 755TR regenerative drives, PowerFlex 755TM drive systems are

also referred to as PowerFlex 755T drive products.

The PowerFlex 755 drive is used for the examples in this manual.

Terminology Table 1 defines the abbreviations that are used in this manual.

Table 1 - Abbreviations and Definitions

Abbreviation Full Term Definition

Timed SS1 Timed Safe Stop 1 Timed SS1 and Safe Stop 1 time-controlled (SS1-t) are synonymous. Both mean a safe stop where the

motor speed is decelerated to zero and once the maximum stop-time elapses, torque is removed from

the motor.

• Safe Stop 1 time-controlled (SS1-t) is according to IEC 61800-5-2.

SS1-t Safe Stop 1 time-controlled

Monitored SS1 Monitored Safe Stop 1 Monitored SS1and SafeStop1ramp-monitored(SS1-r) aresynonymous.Bothmeanasafestopwhere

themotor speed is reducedtostandstillwithindecelerationlimits and oncestandstillspeedis reached

or the maximum stop-time elapses, torque is removed from the motor.

• Safe Stop 1 ramp-monitored (SS1-r) is according to IEC 61800-5-2.

SS1-r Safe Stop 1 ramp-monitored

1oo2 One out of Two Refers to the behavioral designof 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 ISO 13849-1).

CL Claim Limit ThemaximumSILratingthatcanbeclaimedforasafety-relatedelectricalcontrolsystemsubsystemin

relation to architecturalconstraints and systematic safety integrity (sourceIEC 62061).

CIP™ Common Industrial Protocol Protocol for industrial automation applications and trademarked by ODVA, Inc.

EN European Norm The official European Standard.

ESD Emergency Shutdown Systems A system, usually independent of the main control system, which is designed toshut down an

operating system safely.

ESPE Electro-sensitive Protective Equipment

An assembly of devices and/or components working together for protective tripping or presence-

sensing purposes and includes as a minimum:

•Asensingdevice.

• Controlling/monitoring devices.

• Output signal-switching devices (OSSD).

HFT Hardware Fault Tolerance The HFT equals n, where n+1 faults could cause the loss of the safety function. An HFT of one means

that two faults are required before safety is lost.

HIM Human Interface Module A module that is used to configure a device.

IEC International Electrotechnical Commission The International Electrotechnical Commission (IEC) is the organization that prepares and publishes

international standards for all electrical, electronic, and related technologies.

IGBT Insulated Gate Bi-polar Transistors Typical power switch that is 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.

NC Normally Closed A set of contacts on a relay or switch that are closed when the relay is de-energized or the switch is de-

activated.

NO Normally Open A set of contacts on a relay or switch that are open when therelay is de-energized or the switch is de-

activated.

OSSD Output Signal Switching Device The component of the electro-sensitive protective equipment (ESPE) connected to the control system

of a machine. When the sensing device is actuatedduring normal operation, the device responds by

going to the OFF-state.

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.

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