ABB ACS880-07 User manual

Options for ABB drives
User’s manual
Prevention of unexpected start-up (option +Q950)
for ACS880-07/17/37 drives

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
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Drive hardware manuals and guides Code (English)
ACS880-07 drives (560 to 2800 kW) hardware manual 3AUA0000143261
ACS880-07 drives (45 to 630 kW, 50 to 700 hp) hardware
manual
3AUA0000105718
ACS880-17 drives (160 to 3200 kW) hardware manual 3AXD50000020436
ACS880-37 drives (160 to 3200 kW) hardware manual 3AXD50000020437
ACS880-17 drives (45 to 400 kW) hardware manual 3AXD50000035158
ACS880-37 drives (45 to 400 kW) hardware manual 3AXD50000035159
Drive firmware manuals and guides
ACS880 primary control program firmware manual 3AUA0000085967
ACS880 primary control program quick start-up guide 3AUA0000098062
ACS880 diode supply control program firmware manual 3AUA0000103295
ACS880 IGBT supply control program firmware manual 3AUA0000131562
PC tool manuals
Start-up and maintenance PC tool Drive composer user’s
manual
3AUA0000094606
Functional safety design tool user’s manual 3AXD10000102417
Option manuals and guides
ACS-AP-x Assistant control panels user’s manual 3AUA0000085685
FSO-12 safety functions module user’s manual 3AXD50000015612
FSO-21 safety functions module user’s manual 3AXD50000015614
FSE-31 pulse encoder interface module user’s manual 3AXD50000016597
Functional safety; Technical guide No. 10 3AUA0000048753
Safety and functional safety; A general guide 1SFC001008B0201
ABB Safety information and solutions www.abb.com/safety
Manuals and quick guides for I/O extension modules,
fieldbus adapters, etc.
ACS880-07 (45 to
710 kW) manuals
ACS880-07 (560 to
2800 kW) manuals
ACS880-17 (160 to
3200 kW) manuals
ACS880-37 (160 to
3200 kW) manuals
ACS880-17 (45 to
400 kW) manuals
ACS880-37 (45 to
400 kW) manuals

User’s manual
Prevention of unexpected start-up (option +Q950)
for ACS880-07/17/37 drives
3AUA0000145922 Rev F
EN
EFFECTIVE: 2018-02-02
2018 ABB Oy. All Rights Reserved.
Table of contents
4. Start-up and acceptance test

5
Table of contents
List of related manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1. Introduction to the manual
Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Applicability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Target audience . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Related documents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Exclusion of liability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Quick reference guide for implementing a safety system . . . . . . . . . . . . . . . . . . . . . . . . 11
2. Option description and instructions
Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Summary of wirings and settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Operation principle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Time scheme . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Operation principle diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Use of the safety function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Activating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Resetting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
POUS indications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Fault reaction function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
FSO module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
FSE module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Safety encoder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
STO function in the drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
3. Parameter settings
Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
FSO module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
General parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Parameters for the STO function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Parameters for the SSE function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Parameters for the POUS function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
FSE module and safety pulse encoder parameters . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Drive parameter settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Safety pulse encoder parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
4. Start-up and acceptance test
Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Safety encoder interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

6
Start-up and acceptance test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Checks and settings with no voltage connected . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Settings with voltage connected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Acceptance test procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
5. Maintenance
Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Proof test interval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Competence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Residual risk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Intentional misuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Decommissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
6. Technical data
Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Safety data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Safety performance with different safety pulse encoders . . . . . . . . . . . . . . . . . . . . . 33
Safety data values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Safety component types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Safety block diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Relevant failure modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Fault exclusions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Operation delays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
General rules, notes and definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Validation of the safety functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Validation procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Acceptance test reports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Competence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Ambient conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Reporting problems and failures related to safety functions . . . . . . . . . . . . . . . . . . . 36
Related standards and directives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Compliance with the European Machinery Directive . . . . . . . . . . . . . . . . . . . . . . . . . 37
Further information
Product and service inquiries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Product training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
Providing feedback on ABB Drives manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Document library on the Internet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Introduction to the manual 7
1
Introduction to the manual
Contents of this chapter
This chapter describes the manual in short and gives some general information for the
reader. The chapter also contains a quick reference for implementing a safety system.
Applicability
The manual applies to ACS880-07/17/37 drives which have the option +Q950: Prevention
of unexpected start-up with STO, with FSO. For the option +Q950, ABB installs the FSO-
12 safety functions module (option +Q973) or the FSO-21 safety functions module (option
+Q972) to the drive. When a safety pulse encoder is used, ABB installs the FSE-31 pulse
encoder interface module (option +L521) and the FSO-21 module to the drive. Only the
FSO-21 module supports the FSE-31 module and the use of safety pulse encoders.
Required versions with the FSO-12 module:
•ACS880 primary control program: 1.80 or later
•FSO-12 safety functions module: revision C or later
•Drive composer pro: 1.6 or later.
Required versions with the FSO-21 module:
•ACS880 primary control program: 2.2 or later
•FSO-21 safety functions module: revision D or later
•FSE-31 pulse encoder interface module: revision D or later (if used)
•Drive composer pro: 1.8 or later.

8 Introduction to the manual
Safety instructions
Only a qualified electrician who has appropriate knowledge on functional, machine and
process safety is allowed to install, start up and maintain the safety circuit.
WARNING! This safety function does not disconnect the voltage of the main and
auxiliary circuits from the drive. Never work on the electrical parts of the drive or
the motor before you have also disconnected the drive system from the electric
supply, from rotating permanent magnet motors and from rotating motors equipped with
sine filters, and made sure by measuring that there is no dangerous voltage present.
WARNING! After you have made additions to the drive safety circuit or modified it,
changed circuit boards inside the drive, replaced the FSO or FSE module or
modified FSO module parameters, always test the operation of the safety circuit
according to its acceptance test procedure. The change can affect unexpectedly. All
customer-made changes are on the customer’s responsibility.
WARNING! The Safe torque off functionality is only achieved through the XSTO
connector of the inverter or drive control unit. True Safe torque off functionality is
not achieved through the XSTO connectors of the supply control unit. In the
supply unit, the XSTO input must not be used for any safety function purposes to ensure
personnel safety. The Safe torque off function is supported by any ACS880 inverter or
drive firmware. It is not supported by supply firmware.
WARNING! (With permanent magnet or synchronous reluctance [SynRM] motors
only) In case of a multiple inverter IGBT failure, the inverter can produce an
alignment torque which maximally rotates the motor shaft by
180/p(with permanent magnet motors) or 180/2p(with synchronous reluctance [SynRM]
motors) degrees regardless of the activation of the Safe torque off function. pdenotes the
number of pole pairs.
WARNING! Read and obey all safety instructions in the drive hardware manual. If
you ignore them, injury or death, or damage to the equipment can occur.
This manual does not repeat the complete safety instructions of the drive but it only
includes the instructions related to the scope of this manual.
Target audience
This manual is intended for people who install, start up, use and service the drive safety
option. Read the manual before working on the drive. You are expected to know the
fundamentals of electricity, wiring, electrical components, electrical schematic symbols,
and functional safety.

Introduction to the manual 9
Contents
The chapters of this manual are briefly described below.
Introduction to the manual (this chapter) introduces this manual and gives safety
instructions.
Option description and instructions describes the safety function and instructs how to wire
and use it.
Parameter settings lists the parameters that you have to set for the safety function.
Start-up and acceptance test gives instructions on how to start up, test and validate the
safety function.
Maintenance gives instructions on how to maintain the safety function.
Technical data gives general rules, notes and definitions related to safety functions and
lists the related standards and directives. The safety data is also given.
Related documents
•Product manuals (see the inside of the front cover)
•Circuit diagrams delivered with the drive
•Part lists delivered with the drive
•Safety data report (if the safety circuit is application engineered)
Abbreviations
Abbreviations used in this manual are listed below.
Abbreviation Description Reference
Cat. Classification of the safety-related parts of a control system. The
categories are: B, 1, 2, 3 and 4.
EN ISO 13849-1
CCF Common cause failure (%) EN ISO 13849-1
DC Diagnostic coverage EN ISO 13849-1
DI Digital input
DO Digital output
HFT Hardware fault tolerance IEC 61508,
EN 62061
Frame (size) Relates to the construction type of the drive in question. For
example, several drive types with different power ratings can have
the same basic construction, and a frame size is used in reference
to all those drive types.
With the ACS880-07/17/37 (smaller), the frame size marking of the
drive indicates the physical size of the drive, eg, R6.
With the ACS880-07 (larger), the frame size marking of the drive
indicates the quantity and frame size of the diode supply modules
plus the quantity and frame size of the inverter modules, eg, “2×D8T
+3×R8i”.
With the ACS880-17 and ACS880-37 (larger), the frame size
marking of the drive indicates the quantity and frame size of the
IGBT supply modules plus the quantity and frame size of the
inverter modules, eg, “2×R8i +3×R8i”.
FSE-31 Pulse encoder interface module
FSO-12 Safety functions module which does not support the use of encoders

10 Introduction to the manual
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.
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.
FSO-21 Safety functions module which supports the FSE-31 module and the
use of safety encoders
GND Ground
HFT Hardware fault tolerance IEC 61508,
EN/IEC 62061
IGBT Insulated gate bipolar transistor
PFDavg Average probability of dangerous failure on demand IEC 61508
PFH Average frequency of dangerous failures per hour IEC 61508
PL Performance level (levels are: a, b, c, d and e). Corresponds to SIL. EN ISO 13849-1
POUS Prevention of unexpected start-up EN 1037
R8i Frame size designation of the inverter unit
SC Systematic capability IEC 61508
SIL Safety integrity level (levels are: 1, 2, 3 and 4) IEC 61508,
IEC 61511,
EN/IEC 62061,
EN/IEC 61800-5-2
SILCL SIL claim limit. Maximum SIL that can be claimed for a safety
function or subsystem
EN 62061
SSE Safe stop emergency
STO Safe torque off. In this manual, this term is used in two different
contexts:
• the STO circuit in the drive (the drive STO function)
• the STO safety function in the FSO module.
Safety functions in the FSO module (eg, STO, SSE, SS1 and
POUS) activate the drive STO function, that is, open the drive STO
circuit. In addition, some safety functions can activate the STO
safety function in the FSO module, which in turn opens the drive
STO circuit.
EN/IEC 61800-5-2
T1 Proof test interval. T1 is a parameter used to define the probabilistic
failure rate (PFH or PFD) for the safety function or subsystem.
Performing a proof test at a maximum interval of T1 is required to
keep the SIL capability valid. The same interval must be followed to
keep the PL capability (EN ISO 13849) valid. Note that any T1
values stated cannot be regarded as a guarantee or warranty.
See also section Proof test interval on page 31.
IEC 61508,
EN/IEC 62061
TP Test pulse
Abbreviation Description Reference