ABB FSE-31 User manual

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OPTIONS FOR ABB DRIVES
FSE-31 pulse encoder interface module
User’s manual

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List of related manuals
You can find manuals and other product documents in PDF format on the Internet. See
section Document library on the Internet on the inside of the back cover. For manuals
not available in the Document library, contact your local ABB representative.
Drive hardware manuals and guides Code (English)
ACS880-01 hardware manual 3AUA0000078093
ACS880-04 hardware manual 3AUA0000128301
ACS880-04 single drive module packages hardware
manual
3AUA0000138495
ACS880-14 and -34 single drive module packages
hardware manual
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ACS880-04XT drive modules (500 to 1200 kW)
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ACS880-07 (560 to 2800 kW) hardware manual 3AUA0000143261
ACS880-17 (160 to 3200 kW) hardware manual 3AXD50000020436
ACS880-37 (160 to 3200 kW) hardware manual 3AXD50000020437
ACS880-17 (132 to 355 kW) hardware manual 3AXD50000035158
ACS880-37 (132 to 355 kW) hardware manual 3AXD50000035159
ACS880-104 hardware manual 3AUA0000104271
ACS880-107 hardware manual 3AUA0000102519
Drive firmware manuals and guides
ACS880 primary control program firmware manual 3AUA0000102519
Option manuals and guides
ACX-AP-x assistant control panels user’s manual 3AUA0000085685
FSE-31 pulse encoder interface module user’s manual 3AXD50000016597
FSO-21 safety functions module user's manual 3AXD50000015614
Drive PC tool manuals
Drive composer start-up and maintenance PC tool
user's manual
3AUA0000094606
Functional safety design tool user’s manual 3AXD10000102417
General safety guides
Functional safety; Technical guide No. 10 3AUA0000048753
Safety and functional safety; A general guide 1SFC001008B0201
ABB Safety information and solutions www.abb.com/safety

6. Commissioning
User’s manual
FSE-31 pulse encoder interface module
1. Safety instructions
Table of contents
4. Mechanical installation
5. Electrical installation
3AXD50000016597 Rev C
EN
EFFECTIVE: 2020-06-05

Table of contents 5
Table of contents
1. Safety instructions
Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Use of warnings and notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Electrical safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2. Introduction to the manual
Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Applicability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Compatibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Target audience . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
General safety system considerations . . . . . . . . . . . . . . . . . . . . 12
Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Terms and abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Exclusion of liability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3. Hardware description
Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Product overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Type designation label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
4. Mechanical installation
Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Necessary tools and instructions . . . . . . . . . . . . . . . . . . . . . . . . 19
Unpacking and examining the delivery . . . . . . . . . . . . . . . . . . . 19
Installing the module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
5. Electrical installation
Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Necessary tools and instructions . . . . . . . . . . . . . . . . . . . . . . . . 23
Terminal designations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Pin allocation of the encoder interface connector 1 (X31) . . 24

6 Table of contents
Pin allocation of the power supply connector (X81) . . . . . . . 24
Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
General guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Installation procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
6. Commissioning
Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Before you start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Required tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Setting the parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Validation of the safety system . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Commissioning test for FSE-31 . . . . . . . . . . . . . . . . . . . . . . . . . 28
7. Diagnostics
Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Faults and warning messages . . . . . . . . . . . . . . . . . . . . . . . . . . 29
LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Safety encoder fault reaction . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
FSE-31 module replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
8. Technical data
Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Dimension drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
General data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Isolation areas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Encoder interface connector 1 (X31) . . . . . . . . . . . . . . . . . . . . . 33
Power supply (X81) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Supported safety encoders . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Supported encoder cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Safety performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Safety data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Related standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Further information

Safety instructions 7
1
Safety instructions
Contents of this chapter
The chapter contains the warning symbols used in this manual and
the safety instructions which you must obey when you install or
connect an option module to a drive. If you ignore the safety
instructions, injury, death or damage can occur. Read this chapter
before you start the installation.
Use of warnings and notes
Warnings tell you about conditions which can cause injury or
death, or damage to the equipment. They also tell you how to
prevent the danger. Notes draw attention to a particular condition
or fact, or give information on a subject.
The manual uses these warning symbols:
Electricity warning tells you about hazards from
electricity which can cause injury or death, or damage to
the equipment.

8 Safety instructions
General warning tells you about conditions, other than
those caused by electricity, which can cause injury or
death, or damage to the equipment.
Electrical safety precautions
These instructions are for all who install or connect an option
module to a drive and need to open its front cover or door to do the
work.
WARNING! Obey these instructions. If you ignore them,
injury or death, or damage to the equipment can occur. If
you are not a qualified electrical professional, do not do
installation or maintenance work.
1. Clearly identify the work location and equipment.
2. Disconnect all possible voltage sources. Make sure that re-
connection is not possible. Lock out and tag out.
•Open the main disconnecting device of the drive.
•If you have a permanent magnet motor connected to the
drive, disconnect the motor from the drive with a safety
switch or by other means.
•Disconnect all dangerous external voltages from the
control circuits.
•After you disconnect power from the drive, always wait 5
minutes to let the intermediate circuit capacitors discharge
before you continue.
3. Protect any other energized parts in the work location against
contact.
4. Take special precautions when close to bare conductors.

Safety instructions 9
5. Measure that the installation is de-energized.
•Use a multimeter with an impedance greater than 1 Mohm.
•Make sure that the voltage between the drive input power
terminals (L1, L2, L3) and the grounding (PE) busbar is
close to 0 V.
•Make sure that the voltage between the drive output
terminals (T1/U, T2/V, T3/W) and the grounding (PE)
busbar is close to 0 V.
6. Install temporary grounding as required by the local
regulations.
7. Ask the person in control of the electrical installation work for a
permit to work.

10 Safety instructions

Introduction to the manual 11
2
Introduction to the manual
Contents of this chapter
This chapter introduces this manual.
Applicability
This manual applies to the FSE-31 pulse encoder interface
module, revision F.
Compatibility
The FSE-31 pulse encoder interface module is compatible with:
•ACS880 primary control program version 2.21 or later
It is recommended to always use the latest drive firmware.
•FSO-21 safety functions module, revision B or later
•Drive composer pro PC tool, version 1.8 or later.
The supported safety encoder type is:
•differential push-pull HTL encoder
Target audience
This manual is intended for people who plan the installation, install,
start up, use and service the module. Before you do work on the

12 Introduction to the manual
module, read this manual and the applicable drive manual that
contains the information for the product in question.
You are expected to know the fundamentals of functional safety,
electricity, wiring, electrical components and electrical schematic
symbols. The manual is written for readers worldwide. Both SI and
imperial units are shown.
General safety system considerations
The FSE-31 module is part of a functional safety system. Any
functional safety system must be validated and verified according
to the functional safety process. For general safety considerations
and information to be taken into account when building a safety
system, see FSO-21 safety functions module user's manual
(3AXD50000015614 [English]).
WARNING! User safety must be ensured by other means
in all of the stages of the product's lifecycle when the
safety option may not provide protection, especially during
commissioning, system maintenance, fault tracing, and
decommissioning.
Contents
The manual consists of these chapters:
•Safety instructions contains the electrical safety instructions
which you must obey when you install the module.
•Hardware description gives a short description of the module.
•Mechanical installation contains a delivery checklist and
instructions on installing the module.
•Electrical installation contains instructions on wiring the
module.
•Commissioning contains instructions on taking the module into
use as a part of a functional safety system.

Introduction to the manual 13
•Diagnostics shows how to trace faults with the status LED on
the module.
•Technical data contains the technical data of the module.
Terms and abbreviations
Exclusion of liability
ABB is not responsible for the implementation, verification and
validation of the overall safety system. It is the responsibility of the
system integrator (or other party) who is responsible for the overall
system and system safety.
Term/abbreviation Description
Fail-safe mode The FSO module has activated the drive STO
function as a result of an error. To exit this mode
and continue normal operation, repair the
possible fault and reboot the FSO module.
FEA-03 F-series extension adapter module
FSO-21 Safety functions adapter module which
supports a safety encoder
hi-Z state A digital signal is neither driven to a logical high
nor low level. It is “floating”.
HTF Hardware fault tolerance. (EN/IEC 62061)
HTL High-threshold logic
Safety system Whole functional safety system including, for
example, human-machine interface (HMI),
safety encoder, FSE-31 module, FSO module,
drive and sensors.
SIL Safety integrity level (levels are: 1, 2, 3, and 4).
Corresponds to PL. (EN 62061)
SILCL Maximum SIL that can be claimed for a safety
function or subsystem. (EN/IEC 62061)
STO Safe torque off
PL Performance level (levels are: a, b, c, d and e).
Corresponds to SIL. (EN ISO 13849-1)

14 Introduction to the manual
The system integrator (or other responsible party) must make sure
that the entire implementation complies with all relevant standards,
directives and local electrical code, and that the system is tested,
verified and validated correctly.

Hardware description 15
3
Hardware description
Contents of this chapter
This chapter gives a short description of the module.
Product overview
The FSE-31 safety pulse encoder interface module delivers speed,
direction and position data from the safety encoder to:
•the functional safety system via the FSO-21 safety functions
module, and
•to the ACS880 drive for motor control.
The FSE-31 module also monitors the operation of the encoder
and indicates faults to the FSO-21 module.
The FSE-31 module supports one HTL safety encoder. The
module has two built-in encoder interface connectors, X31 and
X32. Only X31 can be used. Interface X32 is reserved for future
use and must be left unconnected.
The FSE-31 module needs an external 24 V DC power supply
which must be connected to connector X81. For the safety
encoder, the module provides a 15 V DC power supply through
connector X31. The safety encoder must be powered from this
interface only.
Only one FSE-31 module can be installed to a drive.

16 Hardware description
Risk assessment of the application must determine at least the
following safety critical requirements:
•The need for a safety encoder. ABB recommends to use a
safety encoder if it is necessary to measure the safe speed
close to the zero speed region and in active load applications.
•the required SIL or PL level
•identifying the safety relevant application-specific parameters,
eg, process safety time
•the required encoder resolution
The operation environment of the FSE-31 module must comply
with the specified conditions. See FSO-21 safety functions module
user’s manual (3AXD50000015614 [English]).
If the FSE-31 module fails to operate, replace it with a new one. Do
not try to repair the module.
For instructions on decommissioning the module, see FSO-21
safety functions module user’s manual (3AXD50000015614
[English]).
WARNING! Do not bypass the FSE-31 pulse encoder
interface module or FSO safety functions module under
any circumstances.

Hardware description 17
Layout
67
3
4
1
2
1
5
X31
Pin no.
1
2
3
4
5
6
7
8
9

18 Hardware description
Type designation label
The type designation label is attached on the top of the
FSE module. An example label and description of the label
contents are shown below.
Item Description
1 Retaining clips
2 Lock
3 Mounting/grounding screw
4 Encoder interface connector X31
5 Encoder interface connector X32 (reserved for future use)
6 External power supply X81
7 Diagnostic LEDs
Item Description
1Type
2 Serial number of format RYWWSSSSWS, where
R component revision; A, B, …
Y: Last digit of the manufacturing year: 4, 5, … for 2014, 2015
WW: Manufacturing week: 01, 02, … for week 1, week 2, …
SSSS: Integer starting every week from 0001
WS: Manufacturing location
3 ABB MRP code of the FSE module
4 Combined ABB MRP code, component revision, serial number and
manufacturing location
5RoHSmark
3
5
2
1
4

Mechanical installation 19
4
Mechanical installation
Contents of this chapter
This chapter contains a delivery checklist and instructions on
installing the module.
Necessary tools and instructions
•Torx screwdriver (T10)
For a complete list of tools, see the applicable drive hardware
manual.
Unpacking and examining the delivery
1. Open the option package.
2. Make sure that the package contains:
•FSE-31 pulse encoder interface module
•this manual (not included if the module is installed into the
drive at the factory).
3. Make sure that there are no signs of damage.

20 Mechanical installation
Installing the module
WARNING! Obey the safety instructions. See chapter
Safety instructions. If you ignore the safety instructions,
injury or death can occur.
Install the FSE-31 module onto an option module slot of the drive
control unit. Do not install the FSE-31 module onto an FEA-03
F-series extension adapter.
1. Stop the drive and do the steps in section Electrical safety
precautions on page 8before you start the work.
2. Pull out the lock.
3. Put the module carefully into its position on the drive until the
retaining clips lock it into position.
4. Push in the lock.
5. Tighten the mounting screw. The maximum tightening torque is
0.8 N·m (7.1 lbf·in).
Note: The mounting screw tightens the connections and
grounds the module. It is necessary for fulfilling the EMC
requirements and for proper operation of the module.
WARNING! Tightening the screw too much can cause
damage to the threads.
See the applicable drive manual for further instructions on how to
install the module to the drive.