ABB ACS880-07 User manual

—
OPTIONS FOR ABB DRIVES
Emergency stop, configurable stop category
0 or 1 (option +Q978) for
ACS880-07/07LC/17/17LC/37/37LC drives
User's manual

Emergency stop, configurable stop
category 0 or 1 (option +Q978) for
ACS880-07/07LC/17/17LC/37/37LC
drives
User's manual Table of contents
1. Safety instructions
4. Electrical installation
7. Start-up and acceptance test
3AUA0000145920 Rev G
EN
EFFECTIVE: 2020-07-10

Table of contents
1 Safety instructions
9Contents of this chapter ...........................................................................
9Use of warnings and notes .......................................................................
9Instructions for functional safety circuits ........................................................
10Electrical safety precautions .....................................................................
2 Introduction to the manual
13Contents of this chapter ...........................................................................
13Applicability .........................................................................................
13Target audience ....................................................................................
14Exclusion of liability ................................................................................
14Quick reference guide for taking a safety function into use ..................................
14Related manuals ...................................................................................
16Terms and abbreviations ..........................................................................
3 Option description
17Contents of this chapter ...........................................................................
17Overview ............................................................................................
18Summary of wirings and settings ............................................................
20Operation principle .................................................................................
21Time schemes with a speed estimate (no safety encoder) ...............................
21Emergency stop, stop category 0 ........................................................
22Emergency stop, stop category 1 with time monitoring ...............................
24Emergency stop, stop category 1 with ramp monitoring ..............................
27Time schemes with a safety encoder ........................................................
27Emergency stop, stop category 0 ........................................................
28Emergency stop, stop category 1 with time monitoring ...............................
30Emergency stop, stop category 1 with ramp monitoring ..............................
32Operation principle diagrams .................................................................
32ACS880-07 drives, frames R6 to R11 and ACS880-17/-37 drives, frame R8 .....
33ACS880-07/07LC drives, frames n×DXT + n×R8i .....................................
35ACS880-17/17LC/37/37LC drives, frames n×R8i + n×R8i ...........................
37ACS880-17/37 drives, frame R11 ........................................................
38Fault reaction function .............................................................................
38FSO module .....................................................................................
38Resetting the FSO module ................................................................
39FSE-31 module .................................................................................
39Safety encoder ..................................................................................
39STO function in the drive ......................................................................
4 Electrical installation
41Contents of this chapter ...........................................................................
41Wiring ................................................................................................
42Customer-installed main breaker in ACS880-07LC/17LC/37LC drives ................
Table of contents 5

5 Parameter settings
43Contents of this chapter ...........................................................................
43Competence ........................................................................................
43FSO module parameter settings .................................................................
44General parameters ............................................................................
46Parameters for the STO function .............................................................
48Parameters for the SSE function .............................................................
49I/O parameters ..................................................................................
50Parameters for Emergency stop, stop category 0 .........................................
51Parameters for Emergency stop, stop category 1 .........................................
53Changing the stop category from 0 to 1 .....................................................
54FSE-31 module and safety pulse encoder related parameters ..........................
55Drive parameter settings ..........................................................................
55
Additional parameter settings for ACS880-07/07LC drives, frames n×DXT + n×R8i and
ACS880-17/17LC/37/37LC drives, frames n×R8i + n×R8i ...................................
55Additional parameter settings for ACS880-17/37, frames R8 and R11 ....................
56Safety pulse encoder parameters ...............................................................
56SS1 ramp parameters .............................................................................
6 Use of the safety function
57Contents of this chapter ...........................................................................
57Activating the safety function .....................................................................
58Resetting the safety function .....................................................................
7 Start-up and acceptance test
59Contents of this chapter ...........................................................................
59Validation of the safety functions ................................................................
59Competence .....................................................................................
59Validation procedure ...........................................................................
60Acceptance test reports .......................................................................
60Start-up and acceptance test .....................................................................
8 Maintenance
63Contents of this chapter ...........................................................................
63Safety circuit maintenance .......................................................................
64Proof test interval ..................................................................................
64Competence ........................................................................................
64Residual risk ........................................................................................
64Intentional misuse ..................................................................................
64Decommissioning ..................................................................................
9 Technical data
65Contents of this chapter ...........................................................................
65Safety data ..........................................................................................
65Safety performance with different safety pulse encoders ................................
65Safety data values ..............................................................................
66ACS880-07/07LC drives without the FSE-31 module .................................
66ACS880-07/07LC drives with the FSE-31 module .....................................
67ACS880-17/17LC/37/37LC drives without the FSE-31 module ......................
67ACS880-17/17LC/37/37LC drives with the FSE-31 module ..........................
6 Table of contents

68ACS880-07LC/17LC/37LC drives without a main breaker ............................
68Safety component types .......................................................................
68Safety block diagrams .........................................................................
69
Diagram 1: ACS880-07 drives, six-pulse variants and ACS880-17/37 drives, frame
R8 .............................................................................................
69Diagram 2: ACS880-07 drives, 12-pulse variants with two contactors .............
69
Diagram 3: ACS880-07 drives, 12-pulse variants with a main breaker, and
ACS880-07LC drives .......................................................................
70
Diagram 4: ACS880-17/17LC/37/37LC drives, frames n×R8i + n×R8i and frame
R11 ............................................................................................
70Relevant failure modes ........................................................................
70Fault exclusions ................................................................................
70Operation delays ...............................................................................
70Ambient conditions ................................................................................
71Related standards and directives ................................................................
71Compliance with the European Machinery Directive .........................................
Further information
Table of contents 7

8

Safety instructions
Contents of this chapter
This chapter contains the safety instructions which you must obey when you install, operate
and do maintenance on the safety functions of a drive.
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:
WARNING!
Electricity warning tells about hazards from electricity which can cause injury or
death, or damage to the equipment.
WARNING!
General warning tells about conditions, other than those caused by electricity,
which can cause injury or death, or damage to the equipment.
WARNING!
Electrostatic sensitive devices warning tells you about the risk of electrostatic
discharge which can cause damage to the equipment.
Instructions for functional safety circuits
This manual does not contain the complete safety instructions of the drive. It only includes
the instructions related to the scope of this manual.
1
Safety instructions 9

Only a qualified electrical professional who has sufficient knowledge about functional,
machine, and process safety is permitted to install, start up and maintain the safety circuit.
All user-made changes are on the user's responsibility.
WARNING!
The safety function described in this manual does not isolate the main circuit or
auxiliary circuit from the power supply. Do not do work on the drive, motor cable
or motor before you have isolated the drive system from all power supplies and
measured that there are no dangerous voltages. Before you start the work, do the
steps in section Electrical safety precautions (page 10).
WARNING!
Always test the operation of the safety circuit according to its acceptance test
procedure at the start-up and after any changes to the safety circuit.
WARNING!
Obey the safety instructions of the drive. 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.
Electrical safety precautions
These electrical safety precautions are for all personnel who do work on the drive, motor
cable or motor.
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.
Go through these steps before you begin any 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.
10 Safety instructions
3

5. Measure that the installation is de-energized.
• Before and after measuring the installation, verify the operation of the voltage tester
on a known voltage source.
• Make sure that the voltage between the drive input power terminals (L1, L2, L3)
and the grounding (PE) busbar is zero.
• Make sure that the voltage between the drive output terminals (T1/U, T2/V, T3/W)
and the grounding (PE) busbar is zero.
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.
Safety instructions 11

12

Introduction to the manual
Contents of this chapter
This chapter describes the manual in short and gives some general information for the
reader. This chapter also contains a quick reference guide for implementing a safety system.
Applicability
The manual is applicable to ACS880-07/07LC/17/17LC/37/37LC drives which have the
option +Q978: Emergency stop, configurable stop category 0 or 1 with opening the main
contactor/breaker and STO, with FSO.
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.
Target audience
The manual is intended for people who install, start up, use and service the safety function.
Read the manual before working on the unit. You are expected to know the fundamentals
of electricity, wiring, electrical components, electrical schematic symbols, and functional
safety.
2
Introduction to the manual 13

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 the instructions in this manual, all relevant standards, directives
and local electrical code, and that the system is tested, verified and validated correctly.
Quick reference guide for taking a safety function into use
Task
Connect the user-defined wiring (if any). See the wiring instructions in this manual and the circuit dia-
grams delivered with the drive.
Check and/or set the safety function related parameters (as listed in this manual).
Do the acceptance test to make sure that the implemented system meets the safety requirements. You
can find the instructions for the acceptance test in this manual.
Document the acceptance test procedure. You can find the guidelines for the acceptance test report
in this manual.
Related manuals
CodeManual
Drive hardware
3AUA0000143261ACS880-07 drives (560 to 2800 kW) hardware manual
3AUA0000105718ACS880-07 drives (45 to 710 kW, 50 to 700 hp) hardware manual
3AXD50000569786ACS880-07LC drives hardware manual
3AXD50000020436ACS880-17 drives (160 to 3200 kW) hardware manual
3AXD50000035158ACS880-17 drives (45 to 400 kW) hardware manual
3AXD50000250295ACS880-17LC drives hardware manual
3AXD50000020437ACS880-37 drives (160 to 3200 kW) hardware manual
3AXD50000035159ACS880-37 drives (45 to 400 kW) hardware manual
3AXD50000251407ACS880-37LC drives hardware manual
Drive firmware
3AUA0000085967ACS880 primary control program firmware manual
3AUA0000098062ACS880 primary control program quick start-up guide
3AUA0000103295ACS880 diode supply control program firmware manual
3AUA0000131562ACS880 IGBT supply control program firmware manual
PC tools
3AUA0000094606Drive composer start-up and maintenance PC tool user's manual
TT201312111015Functional safety design tool user’s manual
Safety
3AUA0000048753Functional safety; Technical guide No. 10
1SFC001008B0201Safety and functional safety; A general guide
www.abb.com/safetyABB Safety information and solutions
14 Introduction to the manual

CodeManual
Options
3AUA0000085685ACX-AP-x assistant control panels user’s manual
3AXD50000015612FSO-12 safety functions module user’s manual
3AXD50000015614FSO-21 safety functions module user’s manual
3AXD50000016597FSE-31 pulse encoder interface module user’s manual
Manuals and quick guides for I/O extension modules, fieldbus adapters, etc.
Other documents
Delivered with the driveCircuit diagrams
Delivered with the drivePart lists
Safety data report (if the safety circuit is order-based engineered)
See www.abb.com/drives/documents for all manuals on the Internet.
ACS880-17 (45 to 400 kW) manualsACS880-07 (560 to 2800 kW)
manuals
ACS880-07 (45 to 710 kW) manuals
ACS880-37 (45 to 400 kW) manualsACS880-17LC manualsACS880-17 (160 to 3200 kW)
manuals
ACS880-37LC manualsACS880-37 (160 to 3200 kW)
manuals
Introduction to the manual 15

Terms and abbreviations
DescriptionTerm
Classification of the safety-related parts of a control system in respect of their resistance
to faults and their subsequent behavior in the fault condition, and which is achieved
by the structural arrangement of the parts, fault detection and/or by their reliability.
The categories are: B, 1, 2, 3 and 4. (EN ISO 13849-1)
Cat.
Common cause failure (%) (EN ISO 13849-1)CCF
Frame size designation of the diode supply moduleD8T
Diagnostic coverage (EN ISO 13849-1)DC
Digital input interlockDIIL
Emergency stopE-stop
Physical size of the drive or power moduleFrame, frame size
Optional pulse encoder interface module for safety encoderFSE-31
Optional functional safety modulesFSO-12, FSO-21
Hardware fault tolerance (IEC 61508)HFT
Insulated gate bipolar transistorIGBT
Inverter module(s) under control of one control unit, and related components. One
inverter unit typically controls one motor.
Inverter unit
No modulationmodoff
Normally closedNC
Performance level. Levels a...e correspond to SIL (EN ISO 13849-1)PL
Prevention of unexpected start-upPOUS
Safe acceleration rangeSAR
Safe brake controlSBC
Systematic capability (IEC 61508)SC
Safety integrity level (1...3) (IEC 61508)SIL
Maximum SIL (level 1...3) that can be claimed for a safety function or subsystem
(IEC/EN 62061)
SILCL
Safely-limited speedSLS
Safe stop 1 (IEC/EN 61800-5-2)SS1
Safe stop emergencySSE
Safe torque off (IEC/EN 61800-5-2)STO
There are three categories of stop functions defined by IEC/EN 60204-1:
•stop category 0: an uncontrolled stop where power to the machine actuators is re-
moved immediately (for example, STO)
•stop category 1: a controlled stop where the machine actuators have power for
stopping, after which the power is removed (SS1)
•stop category 2: a controlled stop where the machine actuators continue to have
power (SS2).
Stop category
Supply module(s) under control of one control unit, and related components.Supply unit
Proof test interval. Defines the probabilistic failure rate (PFH or PFDavg) for the safety
function or subsystem. Performing a proof test at a maximum interval of T1is 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 T1values given cannot be regarded
as a guarantee or warranty.
T1
Test pulseTP
16 Introduction to the manual

Option description
Contents of this chapter
This chapter describes the operation and settings of the option +Q978: Emergency stop,
configurable stop category 0 or 1 with opening the main contactor/breaker and STO, with
FSO.
Overview
The option +Q978 uses the FSO-12 safety functions module (option +Q973) or the FSO-21
safety functions module (option +Q972) for the emergency stop safety function. In this
emergency stop option, the Safe torque off (STO) circuit of the drive and the main
contactor/breaker are opened.
ABB installs the FSO module, the main contactor (option +F250) or the main breaker (option
+F255), and the emergency stop circuit to the drive. ABB sets default parameter values for
the option at the factory. The user adjusts the operation of the emergency stop function with
the safety parameters at the start-up, for example, sets the stop category (0 or 1). ABB sets
stop category 0 at the factory.
If option +L521 is selected, ABB installs the FSO-21 safety functions module and FSE-31
pulse encoder interface module to the drive. With this option, you can use a safety encoder
in the application.
Note: The FSE-31 module requires the FSO-21 module. The FSO-12 module is not
compatible with the FSE-31 module or safety encoders.
3
Option description 17

The option +Q978 supports the following emergency stop functions:
• Emergency stop, stop category 0
This is an uncontrolled stop (IEC/EN 60204-1). When the user pushes the emergency
stop button, the Safe torque off (STO) function of the FSO module is activated. This
activates the STO function of the drive and opens the main contactor/breaker. The motor
coasts to a stop.
• Emergency stop, stop category 1
This is a controlled stop (IEC/EN 60204-1). When the user pushes the emergency stop
button, the Safe stop 1 function (SS1) of the FSO module is activated. After the drive
has decelerated the motor speed to a user-defined zero speed limit, the FSO module
activates the STO function of the drive and opens the main contactor/breaker.
The SS1 function can operate in time monitoring or in ramp monitoring mode. In time
monitoring mode, the FSO module monitors that a user-defined deceleration time limit
is not exceeded. In ramp monitoring mode, the FSO module monitors that the motor
decelerates along a user-defined stop ramp.
Note: The safety function request to the FSO module must be active for a minimum of
20 ms.
Note: The main contactor/breaker is controlled with the Safe brake control (SBC) function.
For more information on the SBC function, see the FSO module user's manual.
To be able to start the drive, the user must release the emergency stop button and then
push the emergency stop reset button for 0.3 … 3 s. This resets the emergency stop circuit,
closes the main contactor/breaker and deactivates the drive STO function.
The drive main circuit is de-energized while the emergency stop is active and the main
contactor/breaker is open, but the auxiliary circuit stays energized. Note that activating the
emergency stop function does not isolate the drive or motor from dangerous voltages.
Note: Drives with the Prevention of unexpected start-up (POUS) option (+Q950): If the user
activates the POUS function during the emergency stop deceleration ramp, it overrides the
emergency stop function. This activates the drive Safe torque off (STO) function, opens the
main contactor/breaker and the motor coasts to a stop. For more information on the POUS
safety function, see Prevention of unexpected start-up (option +Q950) for
ACS880-07/07LC/17/17LC/37/37LC drives user’s manual (3AUA0000145922 [English]).
For a detailed description of the drive Safe torque off function, see the hardware manual of
your drive. For more information on the safety functions of the FSO module, see FSO-12
safety functions module user’s manual (3AXD50000015612 [English]) or FSO-21 safety
functions module user’s manual (3AXD50000015614 [English]). For more information on
the FSE-31 module, see FSE-31 pulse encoder interface module user’s manual
(3AXD50000016597 [English]).
The design principles of the option +Q978 comply with EN ISO 13850.
The STO and SS1 functions comply with IEC/EN 61800-5-2. For a complete list of related
standards and European directives, see section Related standards and directives (page 71).
￭Summary of wirings and settings
The wirings and settings of the emergency stop function are:
• The drive is equipped with the FSO safety functions module (option +Q973 or +Q972).
ABB installs the module at the factory.
•One emergency stop button is installed on the cabinet door and wired to the FSO module.
ABB wires the button at the factory. The user can add buttons to the emergency stop
circuit.
18 Option description

• One emergency stop reset button is installed on the cabinet door and wired to the FSO
module. The reset button also includes an emergency stop indication lamp. ABB wires
the button and the indication lamp at the factory. The user can add reset buttons to the
reset circuit.
• The digital output of the FSO module to which the emergency stop indication lamp is
connected, is selected as the output for the Stop completed signal. This is an FSO
module parameter that ABB sets at the factory by default and the user must check at
the start-up.
• The main contactor/breaker is installed inside the cabinet (option +F250 or +F255). The
auxiliary safety relay(s) that control the main contactor/breaker is installed inside the
cabinet and wired to the FSO module. ABB installs and wires the main contactor/breaker
and the auxiliary safety relay(s) at the factory.
• The digital output of the FSO module to which the auxiliary safety relay(s) is connected,
is selected as the output for the Safe brake control (SBC) output signal. This is an FSO
module parameter that ABB sets at the factory by default and the user must check at
the start-up.
Emergency stop, stop category 0:
• The digital inputs of the FSO module to which the emergency stop button is connected,
are selected as the inputs for the STO request. This is an FSO module parameter that
ABB sets at the factory by default and the user must check at the start-up.
Emergency stop, stop category 1:
The user must set these FSO module parameters at start-up:
• The digital inputs of the FSO module to which the emergency stop button is connected,
are selected as the inputs for the SS1 request.
• The SS1 function is set to use either the time monitoring or ramp monitoring mode.
• The stop ramp that is used to decelerate the motor(s) and the monitoring limits (stop
ramp time or ramp monitoring limits) are set according to the application requirements.
Additional wirings and settings when a safety pulse encoder is used:
• The drive is equipped with the FSE-31 pulse encoder interface module (option +L521).
ABB installs the module at the factory.
• The motor must be equipped with a safety pulse encoder. The user installs and wires
the safety pulse encoder to the FSE-31 module. The user must make sure that the
required safety integrity (SIL/PL) can be achieved with the used safety encoder.
Option description 19

Note: The option +Q978 uses the Safe brake control (SBC) function of the FSO module to
control the main contactor/breaker. If you use this option, you cannot use the FSO module
to control a mechanical brake.
Note: In the option +Q978, the drive STO function is used together with the SBC function
of the FSO module, which controls the main contactor/breaker. Thus, every time the drive
STO is opened also the main contactor/breaker is opened. For example, if the Safely-limited
speed (SLS) function (option +Q965) is included in the drive, the main contactor/breaker is
opened after trip limit hits. For more information, see Safely-limited speed with the encoder
interface (option +Q965) for ACS880-07/07LC/17/17LC/37/37LC drives user's manual
(3AXD50000019727 [English]).
Operation principle
The operation and configuration of the emergency stop function is slightly different with and
without a safety encoder. Only the FSO-21 module supports the safety encoder interface,
and you can also use it without a safety encoder.
Note: The Emergency stop, stop category 1 function uses the SS1 function of the FSO
module. The SS1 function uses SAR1 parameters to define the stop ramp. In some situations
(for example, in internal fault situations or due to another safety function) the FSO module
can activate the Safe stop emergency (SSE) function. The SSE function uses SAR0
parameters to define the stop ramp.
Note: If the FSO module activates the SSE function while the SS1 function is active, the
SSE function overrides the SS1 function. Therefore, SAR0 parameters are used instead of
SAR1 parameters to define the stop ramp. You must take this into account when you use
the SS1 function to implement an emergency stop (stop category 1).
20 Option description