Rockwell Automation Allen-Bradley PowerFlex 7000L User Manual

PowerFlex 7000 Series
Safe Torque Off
Bulletin Numbers 7000A, 7000, 7000L
User Manual
Original Instructions
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.
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).
2
Rockwell Automation Publication 7000-UM203D-EN-P - September 2020
Table of Contents
Preface
About This Publication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Download Firmware, AOP, EDS, and Other Files . . . . . . . . . . . . . . . . . . . .
Summary of Changes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Additional Resources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Abbreviations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5
5
5
6
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Optical Interface Boards 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replace Optical Interface Board 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Optical Interface Base Board Safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replace Optical Interface Base Board Safety. . . . . . . . . . . . . . . . . . . .
Optical Interface Base Board Safety Test Points . . . . . . . . . . . . . . . .
Rockwell Automation Publication 7000-UM203D-EN-P - September 2020
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25
26
27
28
29
3
Appendix A
Specifications
Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Environmental Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Certifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CE Conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Machinery Directive (2006/42/EC) . . . . . . . . . . . . . . . . . . . . . . . . . . . .
EMC Directive (2014/30/EC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
31
31
31
32
32
32
32
Appendix B
Spare Parts and Preventative
Maintenance
Spare Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Preventative Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Appendix C
History of Changes
4
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Rockwell Automation Publication 7000-UM203D-EN-P - September 2020
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
Updated standard number that STO satisfies
Updated all safety standards applied to STO
Updated safety standard number
Updated machinery directive standards
Updated EMC directive number and standard
Updated EU Declaration of Conformity
Added History of Changes appendix
Rockwell Automation Publication 7000-UM203D-EN-P - September 2020
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8
10
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32
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37
5
Additional Resources
These documents contain additional information concerning related products
from Rockwell Automation.
Resource
HMI Interface Board Software Updater and Firmware Download Procedure,
publication 7000-QS002
PowerFlex 7000 Medium Voltage AC Drive (Firmware Version 11.xxx) - ForGe
Control, publication 7000-TD002
PowerFlex 7000 Medium Voltage AC Drive (ForGe Control) - Troubleshooting
Guide, publication 7000-TG002
Description
Provides the procedure to update the HMI board software.
Provides complete parameter listing for all PowerFlex 7000 medium voltage drives.
Provides fault and warning messages, spare parts, and fault and warning codes for all
PowerFlex 7000 medium voltage drives.
Provides detailed information on hardware replacement, overview, control and power
PowerFlex 7000 Medium Voltage AC Drive (A Frame) - ForGe Control,
component definition, maintenance and specifications for air-cooled medium voltage
publication 7000A-UM200
variable frequency drives.
Provides detailed information to configure, set up, operate, update and troubleshoot the
PowerFlex 7000 HMI Offering with Enhanced Functionality,
PowerFlex 7000 HMI Interface Board.
publication 7000-UM201
Provides detailed information on hardware replacement, overview, control and power
PowerFlex 7000 Medium Voltage AC Drive (B Frame) - ForGe Control,
component definition, maintenance and specifications for air-cooled medium voltage
publication 7000-UM202
variable frequency drives.
Provides detailed information on hardware replacement, overview, control and power
PowerFlex 7000 Medium Voltage AC Drive (C Frame) - ForGe Control,
component definition, maintenance and specifications for liquid-cooled medium voltage
publication 7000L-UM301
variable frequency drives.
Describes how to configure and use EtherNet/IP devices to communicate on the EtherNet/IP
EtherNet/IP Network Devices User Manual, ENET-UM006
network.
Describes basic Ethernet concepts, infrastructure components, and infrastructure features.
Ethernet Reference Manual, ENET-RM002
Provides guidance on how to conduct security assessments, implement Rockwell
System Security Design Guidelines Reference Manual, SECURE-RM001
Automation products in a secure system, harden the control system, manage user access,
and dispose of equipment.
Provides a quick reference tool for Allen-Bradley industrial automation controls and
Industrial Components Preventive Maintenance, Enclosures, and Contact
assemblies.
Ratings Specifications, publication IC-TD002
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
Safety Guidelines for the Application, Installation, and Maintenance of
the form of individual devices or packaged assemblies incorporating solid-state
Solid-state Control, publication SGI-1.1
components.
Industrial Automation Wiring and Grounding Guidelines, publication 1770-4.1 Provides general guidelines for installing a Rockwell Automation industrial system.
Provides declarations of conformity, certificates, and other certification details.
Product Certifications website, rok.auto/certifications.
You can view or download publications at rok.auto/literature.
Abbreviations
Abbreviation
DCavg
Description
DIC
DPM
ForGe
MTTFd
Drive Input Contactor
Drive Processor Module
Fourth Generation Control
OIB2
OIBBS
PFD
Optical Interface Board (Rev. 2)
Optical Interface Base Board Safety
Probability of Failure on Demand
Probability of a Dangerous Failure occurring per
Hour
Power Structure Diagnostic
Pulse Width Modulation
Silicon Controlled Rectifier
Symmetrical Gate Commutated Thyristor
Self-powered SGCT (Power Supply)
Safe Torque Off
Safe Torque Off Retrofit
PFH
PSD
PWM
SCR
SGCT
SPS
STO
STORK
6
Diagnostic Coverage (Average)
Mean Time to Dangerous Failure
Rockwell Automation Publication 7000-UM203D-EN-P - September 2020
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.
Rockwell Automation Publication 7000-UM203D-EN-P - September 2020
7
Chapter 1
General Description
Safety Standards Applied
To Safe Torque Off Option
8
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
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.
Rockwell Automation Publication 7000-UM203D-EN-P - September 2020
9
Chapter 2
Safety Concept
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.
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.
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.
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.
10
Rockwell Automation Publication 7000-UM203D-EN-P - September 2020
Chapter 2
Functional Proof Tests
The functional safety standards require that functional proof tests be
performed on the equipment used in the system. Proof tests are performed at
user-defined intervals and are dependent upon the Probability of Failure on
Demand (PFD) and Probability of a Dangerous Failure occurring per Hour
(PFH) values.
IMPORTANT
PFD and PFH Definitions
Safety Concept
Your specific application determines the time frame for the proof
test interval.
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
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 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 satisfactorily
perform its safety function on demand or, simply, average PFD. The SIL value
for a High Demand/continuous mode safety-related system is directly related
to the PFH.
Safety Parameter Data
PFH calculations are based on the equations from Part 6 of IEC 61508. MTTFd
and DCavg values are based on ISO 13849-1.
This table provides data for a 12-year mission time only if the safety function is
demanded at least once every 6 months, and demonstrates the worst-case
effect of various drive configuration changes on the data.
Table 1 - Reliability Data for 12-year Mission Time Test
Attribute
PFH
SIL CL
PL
Category
MTTFd
Value(1)
2.26 E-8 1/hour
3
e
3
803 years
DCavg
90%
HFT
PTI (Proof Test Interval)
1
12
(1) STO data for all medium voltage drive frames.
Rockwell Automation Publication 7000-UM203D-EN-P - September 2020
11
Chapter 2
Safety Concept
The Safe State encompasses all operation that occurs outside of the other
monitoring and stopping behavior of the drive as defined as part of the normal
operation without the Safe Torque Off Option.
Safe State
If a Functional Safety System Fault is detected, the safety option goes to the
Safe State. This includes faults related to integrity of hardware or firmware.
Safety Reaction Time
The safety reaction time is the amount of time from a safety-related event as
input to the system until the system is in the Safe State.
The safety reaction time from an input signal condition that triggers a safe
torque off to safe state reached is 1000 ms (maximum).
IMPORTANT
Considerations for Safety
Ratings
An input signal condition that is present for less than the reaction
time may not result in the safety function being performed. A
request of the safety function for less than the reaction time may
result in the detection of a fault.
The achievable safety rating of an application using the safety option installed
in PowerFlex 7000 drives is dependent upon many external factors.
For applications that rely on the immediate removal of power to the actuator,
resulting in an uncontrolled coast to stop, a safety rating up to and including
SIL CL3, PLe, and Cat. 3 can be achieved.
Contact Information if
Safety Option Failure
Occurs
12
If you experience a failure with any safety-certified device, contact your local
Rockwell Automation distributor. With this contact, you can:
• return the components to Rockwell Automation so the failure is
appropriately logged for the catalog number affected and a record is
made of the failure.
• request a failure analysis (if necessary) to determine the probable cause
of the failure.
Rockwell Automation Publication 7000-UM203D-EN-P - September 2020
Chapter
3
Operation, Installation, and Wiring
PowerFlex 7000 Drive Safe
Torque Off Operation
The PowerFlex™ 7000 Drive Safe Torque Off option disables the rectifier and
inverter SGCTs by removing the power supply to the fiber optic transmitters
that command the devices to turn on, and disabling the gating signals to those
fiber optic transmitters. The system satisfies the requirements of SIL3 for safe
turn off of torque. Figure 1 shows the block diagram of the STO option in the
PowerFlex 7000 drive.
The Safe Torque Off option is intended to be part of the safety related control
system of a machine. Before installation, a risk assessment should be
performed that compares the Safe Torque Off option specifications and all
foreseeable operational and environmental characteristics of the machine to
which it is to be fitted.
A safety analysis of the machine section controlled by the drive is required to
determine how often the safety function should be tested for proper operation
during the life of the machine.
The STO option is available in two types. The 24STO option is installed during
manufacturing of the drive and is intended for new drives. The 24STORK
retrofit option is intended for existing drives and is located on the LV Door
(see STO System Components Location on page 23) and must be installed by
Rockwell Automation.
ATTENTION: The following information is merely a guide for proper
installation. Rockwell Automation, Inc. cannot assume responsibility for the
compliance or the noncompliance to any code, national, local or otherwise
for the proper installation of this equipment. A hazard of personal injury
and/or equipment damage exists if codes are ignored during installation.
IMPORTANT
The Safe Torque Off option does not eliminate dangerous
voltages at the drive output. Input power to the drive must be
turned off and safety procedures followed before performing any
electrical work on the drive or 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: By itself, the PowerFlex 7000 Drives Safe Torque Off option
initiates a coast-to-stop action. Additional protective measures will need to
be applied when an application requires a different stopping action.
IMPORTANT
The status of the MV drive input device must be configured and
connected correctly to the safety system to prevent faults being
generated. For the system test function to work correctly on an
SPS drive, follow the recommended circuit as shown in Drive
Input Isolation Device Interlock on page 16.
Rockwell Automation Publication 7000-UM203D-EN-P - September 2020
13
Chapter 3
Operation, Installation, and Wiring
Figure 1 - Drive Safe Torque Off Block Diagram
Drive Input Isolation Device
Rectifier
DC Link
Inverter
Medium Voltage Source
M
700S-CF
Safety Control Relay
STO Command and Reset
(Customer Safety Circuit)
MSR127
Safety Relay
Figure 2 - Example of PowerFlex 7000 Drive, Safe Torque Off Connection, Dual Channel
PowerFlex 7000
Gate
GuardMaster
Trojan
D-1200
S12
D-1201
S11
D-1202
S22
D-1203
S21
D-1204
S34
STO Reset
Circuit Status
Circuit shown with guard door closed and system ready for normal drive
operation.
14
Rockwell Automation Publication 7000-UM203D-EN-P - September 2020
Chapter 3
Operation, Installation, and Wiring
Operating Principle
The drive implements a dual channel system interface using an Allen-Bradley™
Minotaur™ MSR127 safety relay unit. Opening the gate door will switch the
input circuits to the safety relay (Figure 2). The output circuits of the safety
relay will signal each OIBBS (one for the rectifier bridge and one for the
inverter bridge) to go to the safe state. Each OIBBS will signal the drive control
to immediately initiate a shutdown causing the power devices to quench the
current in the DC link. After the requested demand for the safety function, the
gating signals are inhibited and the fiber transmitters power is removed.
1000 ms after the requested demand for the safety function, the STO active
light on the door illuminates, indicating the system is in the safe state. The
drive status on the PanelView™ 1000 will show ‘not ready’ and parameter P699
‘Drive Not Ready 2’ bit 3 will be asserted. To restart the drive, close the gate
door, and press the STO reset button followed by a valid start command to the
drive (Figure 2).
Safe State
is reached
(1 s delay)
Safe Torque Off ON –
motor coasts to a stop
Motor Power is returned when
the safety demand has ended
and motor is restarted
Safe Torque Off Demand
Motor Rotational Power
Safe State Reached
ATTENTION: It is possible to configure the MSR127 for an automatic reset.
This must only be done if a system level risk analysis has been done to deem
this method acceptable for the application.
IMPORTANT
The outputs that switch the STO active light On (on the drive door)
are only for indication and are not safety related outputs.
Fault Detection
A single fault detected on the Allen-Bradley Minotaur MSR127 safety input
circuits will result in the lock-out of the system at the next operation and will
not cause loss of the safety function.
Single faults detected on the other system components (for example, OIBBS,
power structure) will result in the demand for the safety function and a lockout of the system until the faults are corrected and a drive reset is executed.
Application Considerations
When the hazard analysis for the overall machine determines the need for
external mechanical brakes or other stopping means, the external means shall
be activated after the removal of power for Stop Category 0.
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Chapter 3
Operation, Installation, and Wiring
Wiring to the safety components in the drive must be in accordance with the
following steps and must be carried out by competent personnel.
Wiring
Important points to remember about control wiring:
• Always use tinned copper wire.
• Wire with an insulation rating of 600V or greater is recommended.
• Control wires should be separated from power wires by at least
0.3 meters (1 foot).
• Safety input wiring must be protected against external damage by cable
ducting, conduit, armored cable, or other means.
• Shielded cable is required.
• Refer to the Power and Control Wiring section of the applicable
PowerFlex 7000 User Manual
Table 2 - Safe Torque Off Option Terminal Block Specifications
Wire Size Range
Maximum
Minimum
5.2 mm2 (10 AWG)
0.3 mm2 (22 AWG)
Wire Type
Strip Length
Single or Multi-conductor cable 10 mm (0.39 in.)
D-1200
D-1201
D-1202
D-1203
D-1204
Table 3 - VFD6 Terminal Description
Drive Input Isolation Device
Interlock
IMPORTANT
Terminal
Name
D-1200
S12
D-1201
S11 (via OIBBS)
D-1202
S22 (via OIBBS)
D-1203
S21
D-1204
S34
Description
Safety Input N.C. (Ch 1)
Safety Input N.C. (Ch 2)
Reset
The term “Drive Input Isolation Device” refers to an electrically
held contactor or a circuit breaker with an undervoltage trip
circuit used as the drive input device.
The STO option requires both an interlock to open the drive input isolation
device and a feedback monitoring status to indicate the drive input isolation
device status.
Refer to the electrical drawings to show the proper interlocking based on the
type of input device used in the application. In all cases, the interlock connects
to the emergency stop input of the input device.
ATTENTION: Interlocking to a drive input isolation device must be done in
accordance with the recommendations in this manual and the system’s
electrical drawings.
ATTENTION: Do not use mechanically held input contactors as a drive input
isolation device. The safety system must be able to open the drive input
isolation device if a failure of the drive’s power structure is detected.
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Chapter 3
Operation, Installation, and Wiring
Based on the type of input device that is upstream of the PowerFlex 7000, there
are requirements that must be met to insure proper operation of the STO
option. Table 4 shows the required feedback contacts from the drive input
isolation device based on the input device option. For more details, see
publication7000-AT002 and 7000-AT003.
Table 4 - Feedback Contacts Based on Input Device
Input Option
Auxiliary Contacts Required by
Drive without STO Option
Starter/Circuit Isolation
Breaker
Switch
Auxiliary Contacts Required by
Drive with STO Option
Starter/Circuit Isolation
Breaker
Switch
Notes
Remaining spare
contacts on
contactor are 1 NO
and 1 NC for light or
aux relay options
Internal/External
Starter
(Allen-Bradley 1512 1 NO, 1 NC
with IntelliVAC™)(1)
3 NO, 1 NC
1 NO, 2 NC
3 NO, 2 NC
External Starter
(Customer
Supplied)
1 NO
2 NO, 1 NC
1 NO, 1 NC
Circuit Breaker
(Allen-Bradley or
Customer
Supplied)
1 NO
1 pretrip, 1 NO
N/A
1 pretrip, 1 NO, 1
NC
N/A
STO requires UV
relay to trip circuit
breaker in addition
to existing control
method from DIC
relay
(1) Additional relay for STO is mounted in the LV starter cabinet.
When using an Allen-Bradley Bulletin 1512 starter or if the starter is built into
the drive, a relay is added (CNT_AUX_RLY) and wired for the STO option to
generate the proper logic required to meet the feedback requirements. The
following shows the circuit used when the Allen-Bradley starter is external (see
Electrical Drawings).
Figure 3 - Allen-Bradley Drive Input Starter Circuitry Requirements for Safe Torque Off
Control
Supply
Drive Input
Starter Feedback
When a customer’s drive input starter/disconnect is used, the circuit shown in
Figure 4 for the feedback to the STO system is used. This is in addition to the
interlocking already needed for the drive.
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Chapter 3
Operation, Installation, and Wiring
Figure 4 - Customer-supplied Drive Input Starter Circuitry Requirements for Safe
Torque Off
Drive Input
Starter Feedback
Control
Supply
When a drive input circuit breaker is used as the drive input isolation device,
only a NC contact is needed for the STO option (Table 4). Figure 5 shows the
connection requirements of this contact.
Figure 5 - Drive Input Circuit Breaker Circuitry Requirements for Safe Torque Off
Control
Supply
Drive Input Circuit
Breaker Feedback
A dry contact is supplied that must be inserted to either the emergency stop
input of the starter (in the case of an internal/external Allen-Bradley or
customer-supplied starter) or the undervoltage dropout circuit if the drive
input isolation device is a circuit breaker. The terminal points are DI-14A and
DI-1.
In all cases, Figure 6 shows the dependency of the feedback status with
medium voltage applied and the requirements when the interlock contact trips
the drive input isolation device.
Figure 6 - Timing Diagram
Drive Input Isolation
Device Feedback
(wire 509A)
MV Applied
Interlock contact to
input device
(wire DI-14A)
0.5 s max.
1 s max.
18
2 cycles max.
Rockwell Automation Publication 7000-UM203D-EN-P - September 2020
Chapter 3
Product Compatibility
Operation, Installation, and Wiring
The STO option is not compatible with these PowerFlex 7000 configurations:
•
•
•
•
18 Pulse SCR rectifiers
SGCT redundant devices (for example, N+1, N-1 configurations)
Parallel drives
Use of bypass contactor (for example, synchronous transfer, separately
controlled bypass contactor)
• Mechanically-held drive input contactors (for example, option 3950_)
• Versions of the drive firmware prior to 10.002
• Versions of the drive hardware prior to ForGe control
The STO option does not allow for:
• Automatic restart if medium voltage is interrupted for long enough to
discharge the gate driver power supplies on an SPS rectifier.
• More than a 200 ms ride through capability of the input starter control
with an IntelliVAC contactor control module (see 1503-UM053).
Parameter Setup
All PowerFlex drive parameters related to the STO option are in the functional
safety group. Functional Safety Mode is the only writable parameter, and must
match the hardware installed (for other drive configuration parameters, see
Table 5). If this parameter is enabled, there must be OIBBS and OIB2s installed
to run the drive. The access mode must be at least advanced to change this
parameter (see publication 7000-UM201).
Figure 7 - Functional Safety Mode
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Chapter 3
Operation, Installation, and Wiring
Table 5 - Parameter Settings
Group
Drive Hardware Group
Parallel Drive Group
Feature Select Group
Parameter Name
Number of Devices (P145/P146)
Rectifier Type (P153)
Bypass Contactor (Hardware Options 1 – P141)
Redundant Devices (Hardware Options 1 – P141)
Status
Number of installed OIB2s
6 PWM
Unchecked
Unchecked
Must match SPS jumper on
SPS Drive (Hardware Options 2– P274)
rectifier OIBBS
Drives in System (P745)
Set to 1
Powerup Config (P717)
Single
Synchronous Transfer (Special Features – P99) Unchecked
SPS Jumper Settings
See Figure 12 for SPS jumper location on the OIBBS.
1. Ensure the SPS jumper on the rectifier OIBBS is installed if the drive is
installed with an SPS rectifier.
2. Ensure the SPS jumper on the inverter OIBBS is not installed.
Commissioning
Follow the commissioning procedure in the user manual pertaining to the
drive frame size (see Additional Resources on page 6).
IMPORTANT
Verify Operation
When using the System Test mode with the STO option and an SPS
rectifier, follow input device interlock requirements.
Test the safety function for proper operation after initial installation of the
drive or STO retrofit kit. Retest the safety function at the intervals determined
by the safety analysis described on page 13. Perform these procedures after the
drive commissioning procedure is complete.
IMPORTANT
The input component of the STO system in the drive is an AllenBradley Minotaur MSR127 Safety Relay. Perform an STO functional
test at least once every six months to maintain the safety rating.
Verify the interlocking of the drive input isolation device and the ability of the
STO system to open this device.
Table 6 - Power Up
Complete? Description
Upon power up of the drive, ensure there is no fault code 657 or code 689 (i.e., Rec
InpCtrctrClsd or Inv InpCtctrClsd).
Reset any faults in the drive, and put the system in the normal running state (i.e., reset the
STO active state).
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Chapter 3
Operation, Installation, and Wiring
Table 6 - Power Up
Complete? Description
Run the drive above 5 Hz and ensure Rec General Flt (code 639) and Inv General Flt (code
671) are not generated because the input device feedback for the STO system is not the
correct status.
Stop the drive and set the input contactor to critical faults. This parameter is in the feature
select group, P1 Input Ctctr Cfg.
a. Reset any faults that exist and reset the STO feature. The input device should be on
and supplying MV to the drive. Ensure the drive is NOT running.
b. Remove any one of the fiber optic cables on the inverter OIB2s.
c. Verify that relays KG_STO and KG_DIC open, and that the drive input device opens. The
only fault generated should be an Inverter PSD fault 690.
d. Reinstall the fiber optic cable, ensuring it is seated properly.
e. Reset any faults that exist and reset the STO feature. The input device should be on
and supplying MV to the drive. Ensure the drive is NOT running.
f. Using a screwdriver, force the white indicator in on relay KG_DIC so it does not open
for steps g. and h.
g. Remove any one of the fiber optic cables on the inverter OIB2s.
h. Verify that relay KG_STO opens and the drive input device opens. The only fault
generated should be an Inverter PSD fault 690.
Reinstall the fiber optic cable, ensuring it is seated properly. Reset the faults and STO
feature. Ensure any changed parameters are set back to the correct state.
This procedure involves causing a demand for the safety function. Verify that
1 second after the demand for the safety function, the following is true:
Table 7 - STO Activation
Complete? Description
Both channels on the MSR127 safety relay switch off.
CH1 and CH2 status indicators
must switch OFF when a demand
for the safety function is
requested
There are no STO related faults on the drive and parameters Rec Safe Supply and Inv Safe
Supply (P1062 and 1074) show <0.2V. Note that service level access is required to view these
parameters.
The STO active indicator light illuminates on the door.
The drive status on the PV1000 shows not ready and parameter P699 'Drive Not Ready 2' bit
3 is checked.
Parameters Rec OIBBS Status 1 and Inv OIBBS Status 1 (P1057 and P1069) have their 'STO
Active' bits checked.
The motor coasts if it was running and the drive will not start.
Verify the STO system can be reset.
Table 8 - STO Deactivation
Complete? Description
Reset the STO safety device that caused the demand for the safety function.
– Verify the drive cannot be started.
Reset the STO function via the hardwire STO reset.
– Verify the drive can now be started.
IMPORTANT
Submit a copy of Table 6, Table 7, and Table 8 (signed off by the
Field Service Engineer) to MV Tech Support to indicate the drive
component of the functional safety system has been
commissioned and functions correctly.
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Chapter 3
Operation, Installation, and Wiring
Notes:
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Chapter
4
System Components
STO System Components
Location
The location of the 24STO option components is the same for all
PowerFlex™ 7000 drive frame sizes and configurations (Figure 8). The STO
system components are mounted on a DIN rail in the Low Voltage cabinet
above the Control Board Panel and shown in detail in Figure 9. The OIB2 and
OIBBS boards are located behind the Hinged Panel above the DC to DC Power
Supply.
The 24STORK retrofit option has the system components mounted on the Low
Voltage Cabinet door (Figure 10) or in the Low Voltage Cabinet depending on
the available space.
Both 24STO and 24STORK options have an indicator light on the LV cabinet
door.
Figure 8 - Safe Torque Off Option Location for 24STO
STO System
Components
Optical Interface
Boards 2 (OIB2)
Optical Interface Base
Board Safety (OIBBS)
Hinged Panel (open)
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Chapter 4
System Components
Figure 9 - STO System Components Detail
Safety Relay
(440R-N23132)
D-1200
D-1201
D-1202
D-1203
D-1204
Terminal Blocks (1492-JR-RE)
Supplementary Protector
(PN-D165417)
End Anchor
(1492-EAJ35)
Customer Interface
Points
Safety Industrial Relay
(PN-35744)
AC/DC Power Supply
(1606-XLP50E)
Figure 10 - Safe Torque Off Option Location for 24STORK
Optical Interface
Boards 2 (OIB2)
(PN-271938)
Optical Interface Base
Board Safety (OIBBS)
(PN-504125)
STO System Components
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Chapter 4
Optical Interface Boards 2
System Components
The Optical Interface (OIB2) Boards are the interface between the DPM/OIBBS
and the Gate Driver circuitry. The drive control decides which device to fire,
and sends an electrical signal to the OIB2 boards via the OIBBS boards. The
OIB2 board converts that electrical signal to an optical signal, which is
transmitted via fiber optics to the gate driver cards. Typically, the Transmit
ports are Grey and the Receive ports are Blue. The gate driver accepts that
signal and turns the device on and off accordingly. The diagnostic fiber optic
signals work the same way, but the source is the gate driver boards and the
destination is the drive control boards. Each OIB2 contains one extra fiber
optic receiver (RX7), which is used for temperature measurement.
The OIB2 boards differ from the OIB boards in that the transmitter power can
be turned off while the receiver power stays on. This allows for diagnostic
feedback of the power devices while the drive is in a safe state.
Figure 11 - Optical Interface Board
The OIB2 boards are mounted directly on the Optical Interface Base Board
Safety (OIBBS) using two parallel 14-pin connectors for the electrical
connection, and metal standoffs to provide the mechanical support. There is
one OIBBS for the inverter, and one OIBBS for the rectifier devices. The
OIBBSs are interfaced to the DPM using two ribbon cables to connect to J11
and J12. The OIBBS has four Phoenix connectors which connect the board to
the safety system.
Each OIB2 board can handle the Firing and Diagnostic duplex fiber optic
connector for six devices. Physically, on the OIBBS, there is provision for
18 devices for the inverter and the rectifier. This is enough capacity to handle
the highest rated drive that we currently produce. The top OIB2 board on the
OIBBS is for the ‘A’ devices, the middle OIB2 board on the OIBBS is for the ‘B’
devices, and the bottom OIB2 board on the OIBBS is for the ‘C’ devices. Test
points for the OIB2 gating diagnostics and temperature feedback signal are on
the OIBBS.
Each OIB2 also has input RX7 for a signal from a Temperature Feedback
Board. The quantity and location of thermistor connections is dependent on
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Chapter 4
System Components
the drive configuration. Typically there is one temperature sensor from the
Line Converter and one temperature sensor from the Machine Converter, each
going into the respective OIB2 in the ‘A’ position. However some drive
configurations only require one thermistor feedback connection. The
temperature feedback connection on OIB2C is not implemented on the OIBBS
and is never used. For more information, see the drawings supplied with your
drive. The alarm and trip set points for each of these signals is programmable
in software.
There are three status indicators on the OIB2. The following table illustrates
the status and description for the status indicator states:
Status Indicator
Status
D1
Red – On
D2
Yellow – On
D3
Green – On
Description
Run – The OIB2 has received an Enable signal. The drive
control software is in control of all gating.
Ready –The OIB2 power supply is sufficient for proper
operation.
Power – The OIB2 has received a voltage signal greater than
2V.
D3 –On
D1 and D2 – Off
Drive is powered and is in the safe state.
Replace Optical Interface Board 2
ATTENTION: Ensure that all medium voltage and control voltage power to
the drive is isolated and locked out.
1. Note and mark the location and orientation of all the fiber optic cables.
Use the electrical drawing for reference.
2. Using your static strap, disconnect all of the connections. It may be
necessary to remove the 60 core cable connectors on the Optical
interface base and the ground connection for access to the standoffs.
3. Remove the OIB2 board from the OIBBS. There are four standoffs that
are secured in place on the OIB2. There is also the 28-pin connection
between the boards, and this connection must be handled carefully to
avoid bending the pins.
4. Install the new OIB2 on the OIBBS. Ensure all four screws for the
standoffs are replaced.
5. Reconnect all fiber optic connections and verify the locations.
6. Apply Low Voltage power and complete a Gating Test, System Test, and
Medium Voltage tests to ensure the new board functions properly.
7. Perform procedures as described in Verify Operation on page 20.
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Chapter 4
System Components
This board provides the mechanical and electrical interconnections between
the OIB2s and the DPM as well as providing the required circuitry to
implement Safe Torque Off. It connects to either J11 or J12 on the DPM via a 60
conductor shielded ribbon cable. Attach the cable’s drain wire to the screw
terminal J8. The remaining connectors on the board complete the electrical
connection of the installed OIB2s to the DPM. Each OIBBS can support from
one to three OIB2s.
Optical Interface Base
Board Safety
1
+
5
+
1 2
9 10
+
Figure 12 - Optical Interface Base Board Safety (OIBBS)
+
1
+
+
+
+
+
+
59
+
60
+
+
28
+
+
1
1
2
+
+
28
+
1
1
2
1
2
1
2
24
1
23
2
5
1
6
2
4 3 2 1
+
28
6
10 9
2 1
10
1
1
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Chapter 4
System Components
There are six status indicators on the OIBBS.
Table 9 - Status Indicators
Status Indicator Status
Off
D4
Green
Red
Flashing
Green
D9
Red
DS1
Yellow – On
DS2
Yellow – On
DS3
Yellow – On
DS4
Yellow – On
Description
Board has no power.
Normal operating condition
Diagnostic processor watchdog timeout or power supply faults
Normal operation
Diagnostic processor faulted
There are no diagnostic faults detected on the OIBBS. This represents
the status of the A3 relay used for the STO system interlock back to the
MSR127
There are no diagnostic faults detected on the OIBBS. This represents
the status of the A4 relay used for the STO system interlock back to the
MSR127
There is no power structure fault detected by the OIBBS. This
represents the status of the A5 relay used for the permissive control of
the drive input device
The OIBBS is in the safe state. This represents the status of the A7 relay
that is used to illuminate the STO active light on the door
Replace Optical Interface Base Board Safety
ATTENTION: Ensure that all medium voltage and control voltage power to
the drive is isolated and locked out.
1. If the OIB2 is also being replaced, note and mark the location and
orientation of all fiber optic cables. Use the electrical drawing for
reference.
2. Using your static strap, remove the OIB2 board from the OIBBS. There
are four standoffs that are secured in place on the OIB2. There is also the
28-pin connection between the boards, and this connection should be
handled carefully. Do not bend the pins.
3. Unplug the four Phoenix connectors J11, J12, J13, and J15.
4. Remove the 60-pin cable connectors on the OIBBS and the ground
connection.
5. Remove the ground nut holding in the OIBBS. There are five standoffs
that snap into place on the OIBBS and they need to be carefully handled
when removing the boards.
6. Install the new OIBBS and reinstall the ground nut.
7. Plug in the OIB2s and reconnect all the cables.
8. Ensure the SPS jumper on the OIBBS is set correctly (see Figure 12).
9. Apply Low Voltage power and complete a Gating Test, System Test, and
Medium Voltage tests to ensure the new board functions properly.
10.Perform procedures as described in Verify Operation on page 20.
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Chapter 4
System Components
Optical Interface Base Board Safety Test Points
In addition to the command and diagnostic test points, there are three ground
reference test points. These reference points are electrically identical, but their
locations facilitate oscilloscope or chart recorder test leads connections.
Table 10 - OIBBS Test Points
Test Point
TP1
TP2
TP3
TP4
TP5
TP6
TP7
TP8
TP9
TP10
TP11
TP12
TP13
TP14
TP15
TP16
TP17
TP18
TP19
TP20
TP21
TP22
TP23
TP24
TP25
TP26
TP27
TP28
TP29
TP30
TP31
TP32
TP33
TP34
TP35
TP36
TP37
TP38
TP39
TP40
TP41
Signal Name
+5V
DIAG_0
CMD_0
DIAG_1
CMD_1
DIAG_2
CMD_2
DIAG_3
CMD_3
DIAG_4
CMD_4
DIAG_5
CMD_5
TFB_A
GND
DIAG_6
CMD_6
DIAG_7
CMD_7
DIAG_10
CMD_8
DIAG_9
CMD_9
DIAG_8
CMD_10
DIAG_11
CMD_11
TFB_B
GND
DIAG_12
CMD_12
DIAG_13
CMD_13
DIAG_14
CMD_14
DIAG_15
CMD_15
DIAG_16
CMD_16
DIAG_17
CMD_17
TP42
TFB_C
TP43
GND
Description
Positive 5V Power Supply
OIB2 A, RX1 Diagnostic Feedback
OIB2 A, TX1 Firing Command Signal
OIB2 A, RX2 Diagnostic Feedback
OIB2 A, TX2 Firing Command Signal
OIB2 A, RX3 Diagnostic Feedback
OIB2 A, TX3 Firing Command Signal
OIB2 A, RX4 Diagnostic Feedback
OIB2 A, TX4 Firing Command Signal
OIB2 A, RX5 Diagnostic Feedback
OIB2 A, TX5 Firing Command Signal
OIB2 A, RX6 Diagnostic Feedback
OIB2 A, TX6 Firing Command Signal
OIB2 A Temperature Feedback Signal
Ground Reference for TP1 – TP14
OIB2 B, RX1 Diagnostic Feedback
OIB2 B, TX1 Firing Command Signal
OIB2 B, RX2 Diagnostic Feedback
OIB2 B, TX2 Firing Command Signal
OIB2 B, RX5 Diagnostic Feedback
OIB2 B, TX3 Firing Command Signal
OIB2 B, RX4 Diagnostic Feedback
OIB2 B, TX4 Firing Command Signal
OIB2 B, RX3 Diagnostic Feedback
OIB2 B, TX5 Firing Command Signal
OIB2 B, RX6 Diagnostic Feedback
OIB2 B, TX6 Firing Command Signal
OIB2 B Temperature Feedback Signal
Ground Reference for TP16 – TP28
OIB2 C, RX1 Diagnostic Feedback
OIB2 C, TX1 Firing Command Signal
OIB2 C, RX2 Diagnostic Feedback
OIB2 C, TX2 Firing Command Signal
OIB2 C, RX3 Diagnostic Feedback
OIB2 C, TX3 Firing Command Signal
OIB2 C, RX4 Diagnostic Feedback
OIB2 C, TX4 Firing Command Signal
OIB2 C, RX5 Diagnostic Feedback
OIB2 C, TX5 Firing Command Signal
OIB2 C, RX6 Diagnostic Feedback
OIB2 C, TX6 Firing Command Signal
OIB2 C Temperature Feedback Signal – There is no provision in the
drive for the use of this signal, it is only provided for Rockwell
internal testing.
Ground Reference for TP30 – TP42
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System Components
Notes:
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Rockwell Automation Publication 7000-UM203D-EN-P - September 2020
Appendix
A
Specifications
Introduction
General Specifications
This appendix provides general specifications for the PowerFlex™ 7000 drive
Safe Torque Off Option module.
Table 1 - General Specifications
Attribute
Value
IEC
60204-1, IEC 61508, IEC 61800-3, IEC 61800-5-1, IEC 61800-5-2,
Standards
IEC 62061, ISO 13489
Cat. 3 and PLe per IEC 13849-1;
Safety category
SIL CL3 per IEC 61508 and IEC 62061
Safety inputs
2 N.C.
Maximum allowable input resistance 110 Ω
Conductor type
Multi-conductor cable
Conductor size(1)
Strip length
0.3…5.2 mm2 (22…10 AWG)
10 mm (0.39 in.)
(1) Refer to Industrial Automation Wiring and Grounding Guidelines, publication 1770-4.1.
Environmental
Specifications
IMPORTANT
The following are environmental specifications for the OIBBS and
OIB2 boards only. For detailed drive environmental specifications,
see the user manual pertaining to your drive frame size (see
Additional Resources on page 6).
Table 2 - Environmental Specifications
Category
Storage Temperature (all const.):
Shock - Packaged for Shipment
Specification
-40…+70 °C (-40…+158 °F)
381 mm (15 in.) drop height
20.0 mm (0.8 in.) peak to peak, 2…5.186 Hz;
1.1 g peak from 5.186…20 Hz
Vibration - Packaged for Shipment
Sinusoidal Loose Load:
Random Secured:
Frequency (Hz)PSD (g2/Hz)
10.004
20.1008
50.0008
90.012
200.012
1000.00008
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31
Appendix A
Specifications
Certifications
See the Product Certification link at www.rockwellautomation.com/products/
certification/ for Declarations of Conformity, Certificates, and other
certifications details.
Certification(1)
Value
c-UL-us (2)
UL Listed, certified for US and Canada.
CE
European Union 2004/108/EC EMC Directive, compliant with:
IEC 61800-3; PowerFlex 7000 AC Drive, Emissions and Immunity
IEC 62061; Safety Function, Immunity
European Union 2006/42/EC Machinery Directive:
ISO 13849-1; Safety Function
IEC 60204-1; Safety Function
IEC 62061; Safety Function
IEC 61800-5-2; Safety Function
TÜV Rheinland
Certified by TÜV Rheinland for Functional Safety:
up to SIL CL3, according to IEC 61800-5-2, and IEC 62061;
up to Performance Level PLe and Cat. 3, according to ISO 13849-1;
when used as described in this PowerFlex 7000 Drive Safe Torque Off User
Manual, publication 7000-UM203.
(1) When product is marked, refer to www.rockwellautomation.com/products/certification/ for Declarations of
Conformity Certificates.
(2) Underwriters Laboratories Inc. has not evaluated the safe torque-off option for functional safety.
CE Conformity
CE Declarations of Conformity are available online at:
www.rockwellautomation.com/products/certification/
The 24STO and 24STORK Safe Torque Off option is in conformity with the
essential requirements of the 2006/42/EC Machinery Directive and the 2004/
108/EC EMC Directive when installed and maintained in accordance with the
instructions contained in this document. The following standards have been
applied to demonstrate conformity:
Machinery Directive (2006/42/EC)
•
•
•
•
ISO 13849-1:2015 Safety of machinery - Safety related parts of control
systems - Part 1: General principles for design
IEC 60204-1:2016 Safety of machinery - Electrical equipment of
machines - Part 1: General requirements
IEC 62061:2005 + A1:2012 + A2:2015 Safety of machinery - Functional
safety of safety-related electrical, electronic and programmable
electronic control systems
IEC 61800-5-2:2016 Adjustable speed electrical power drive systems Part 5-2: Safety requirement - Functional
EMC Directive (2014/30/EC)
•
32
IEC 61800-3:2017 - Adjustable speed electric power drive systems - Part 3:
EMC requirements and specific test methods
Rockwell Automation Publication 7000-UM203D-EN-P - September 2020
Appendix A
Specifications
EU Declaration of Conformity
Product:
Adjustable Speed Drives Safe Torque Off Options
Name and address of the authorised representative:
Rockwell Automation B.V.
Rivium Promenade 160
2909 LM Capelle aan den Ijssel
The Netherlands
Name and address of the manufacturer:
Rockwell Automation Inc.
1201 South 2nd Street
Milwaukee, WI 53204
U.S.A.
This declaration of conformity is issued under the sole responsibility of the manufacturer.
Object of the declaration:
Medium Voltage PowerFlex7000 Safe Torque Off Options
(reference the attached list of catalogue numbers)
The object of the declaration described above is in conformity with the relevant Union harmonisation legislation:
2014/30/EU
EMC Directive
(EMC)
2006/42/EC
Machinery Directive
(MD)
References to the relevant harmonised standards used or references to the other technical specifications in relation to
which conformity is declared:
IEC 61800-5-2:2016
Adjustable speed electrical power systems – Part 5-2: Safety requirements –
Functional
IEC 61800-5-1:2007 + A1:2016
Adjustable speed electrical power drive systems - Part 5-1: Safety
requirements - Electrical, thermal and energy
IEC 61800-3:2017
Adjustable speed electrical power drive systems — Part 3: EMC requirements
and specific test methods
EN ISO 13849-1:2015
Safety of Machinery – Safety related parts of control systems – Part 1:
General principles for design
IEC 60204-1:2016
Safety of Machinery – Electrical equipment of machines – Part 1: General
requirements
IEC 62061:2005 + A1:2012 +
A2:2015
Safety of Machinery – Functional safety of safety-related electrical, electronic
and programmable electronic control systems
IEC 61508 Parts 1-7:2010
Functional safety of electrical/electronic/programmable electronic safetyrelated systems
Notified Body:
TUV Rheinland Industrie Service GmbH, Am Grauen Stein, 51105, Koln,
Germany
EC Type Examination
01/205/5437.01/20 (MD)
performed:
and issued the certificate(s):
Additional information:
Person authorised to compile the
technical file (MD):
Product Safety Function (MD):
Authorised representative (see details above).
Safe Torque Off
Signed for and on behalf of the above named manufacturer:
Place and date of issue:
Milwaukee, WI, September 1, 2020
Name, function:
Tron Melzl, Manager, Product Compliance Engineering
Signature:
Document Control Number: MVB-0017-A-EN
1/2
Rockwell Automation Publication 7000-UM203D-EN-P - September 2020
33
Appendix A
Specifications
Catalogue number
24STO
24STORK
Series 1
Description
Safe Torque Off Options
Safe Torque Off Options Retrofit
Directive 2
EMC
yes
yes
MD
yes
yes
1) If no series number is given, then all series are certified and covered.
2) No = Product is not certified to this directive.
Yes = Product is certified to this directive.
Document Control Number: MVB-0017-A-EN
2/2
34
Rockwell Automation Publication 7000-UM203D-EN-P - September 2020
Appendix
B
Spare Parts and Preventative Maintenance
Spare Parts
Table 3 Part No.
Description
Optical Interface Base Board Safety
(OIBBS)
Optical Interface Board (OIB2)
Safety Industrial Relay
Safety Relay
XLP 50 W Power Supply
PN-504125
PN-271938
PN-35744
440R-N23132
1606-XLP50E
Quantity
1
1
1
1
1
ATTENTION: In addition to the restart procedure in the user manual,
perform the Verify Operation procedures on page 20 after replacing
any of these components.
The estimated time required to verify if the functional safety system in the
drive is functioning is less than 0.5 hours.
Preventative Maintenance
IMPORTANT
See the PowerFlex™ 7000 user manual for detailed preventative
maintenance schedule and procedure for other non-safety related
parts.
Replace the following parts at 12 year intervals to maintain the SIL rating of the
drive.
Table 4 Part
OIBBS
OIB2
SGCTs
MSR127
Quantity
2
2/4/6 (based on voltage class)
12/24/36 (based on voltage class)
1
Rockwell Automation Publication 7000-UM203D-EN-P - September 2020
35
Appendix B
Spare Parts and Preventative Maintenance
Notes:
36
Rockwell Automation Publication 7000-UM203D-EN-P - September 2020
Appendix
C
History of Changes
This appendix contains the new or updated information for each revision of
this publication. These lists include substantive updates only and are not
intended to reflect all changes. Translated versions are not always available for
each revision.
7000-UM203C-EN-P, September 2018
Topic
Updated Firmware revision to 11.xxx
Added PowerFlex 7000A User Manual to Additional Resources table
Updated OIBBS part number to PN-504125
Updated Safety Industrial Relay to PN-35744
Rockwell Automation Publication 7000-UM203D-EN-P - September 2020
37
Appendix C
History of Changes
Notes:
38
Rockwell Automation Publication 7000-UM203D-EN-P - September 2020
PowerFlex 7000 Series Safe Torque Off User Manual
Rockwell Automation Publication 7000-UM203D-EN-P - September 2020
39
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