ABB ACS880-07CLC User manual

—
OPTIONS FOR ABB DRIVES
Emergency stop, stop category 0 (option
+Q951) for ACS880-07CLC drives
User's manual

Emergency stop, stop category 0
(option +Q951) for ACS880-07CLC
drives
User's manual
Table of contents
1. Safety instructions
4. Electrical installation
7. Start-up and validation test
3AXD50000709830 Rev A
EN
Original instructions
EFFECTIVE: 2021-02-08

Table of contents
1 Safety instructions
7Contents of this chapter ...........................................................................
7Use of warnings and notes .......................................................................
8Instructions for functional safety circuits ........................................................
9Electrical safety precautions .....................................................................
2 Introduction to the manual
11Contents of this chapter ...........................................................................
11Applicability .........................................................................................
11Target audience ....................................................................................
11Exclusion of liability ................................................................................
12Quick reference guide for taking a safety function into use ..................................
12Related documents ................................................................................
13Terms and abbreviations ..........................................................................
3 Option description
15Contents of this chapter ...........................................................................
15Overview ............................................................................................
15Operation principle .................................................................................
17Fault reaction function .............................................................................
17Hardware settings ..................................................................................
4 Electrical installation
19Contents of this chapter ...........................................................................
19Wiring ................................................................................................
5 Parameter settings
21Contents of this chapter ...........................................................................
21Inverter unit parameter settings ..................................................................
21Supply unit parameter settings ...................................................................
6 Use of the safety function
23Contents of this chapter ...........................................................................
23Activating the safety function .....................................................................
23Resetting the safety function .....................................................................
7 Start-up and validation test
25Contents of this chapter ...........................................................................
25Validation of the safety functions ................................................................
25Competence .....................................................................................
25Validation procedure ...........................................................................
26Validation test reports ..........................................................................
26Start-up and validation test .......................................................................
Table of contents 5

8 Fault tracing
29Contents of this chapter ...........................................................................
29Fault tracing .........................................................................................
30Reporting problems and failures related to safety functions .................................
9 Maintenance
31Contents of this chapter ...........................................................................
31Safety circuit maintenance .......................................................................
31Proof test interval ..................................................................................
32Functional safety components ...................................................................
32Competence ........................................................................................
32Residual risk ........................................................................................
33Intentional misuse ..................................................................................
33Decommissioning ..................................................................................
10 Technical data
35Contents of this chapter ...........................................................................
35Safety data ..........................................................................................
35Safety data values ..............................................................................
36Safety component types .......................................................................
36Safety block diagrams .........................................................................
37Relevant failure modes ........................................................................
37Fault exclusions ................................................................................
37Operation delays ...............................................................................
37Ambient conditions ................................................................................
37Related standards and directives ................................................................
38Compliance with the European Machinery Directive .........................................
Further information
6 Table of contents

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.
1
Safety instructions 7

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.
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 or auxiliary
circuits from the power supply. Before you do work on the drive, or its main or
auxiliary circuits, do the steps in section Electrical safety precautions (page 9).
WARNING!
Do the validation test of the safety function at the start-up and also after you make
changes to the safety circuit.
WARNING!
Make sure that the functional safety of the machine is maintained in situations
where the safety option does not provide protection, for example, during
commissioning, system maintenance, fault tracing, or decommissioning.
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.
8 Safety instructions
3

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.
•Open the charging switch if present.
•Open the disconnector of the supply transformer. (The main disconnecting device in
the drive cabinet does not disconnect the voltage from the AC input power busbars
of the drive cabinet.)
•Open the auxiliary voltage switch-disconnector (if present), and all other possible
disconnecting devices that isolate the drive from dangerous voltage sources.
•In the liquid cooling unit (if present), open the switch-disconnector of the cooling
pumps.
•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. If the measurement requires removal or
disassembly of shrouding or other cabinet structures, obey the local laws and regulations
applicable to live working (including – but not limited to – electric shock and arc
protection).
•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.
•Make sure that the voltage between the drive DC terminals (UDC+ and UDC-) and
the grounding (PE) terminal is zero. In cabinet-built drives, measure between the
drive DC busbars (+ and -) and the grounding (PE) busbar.
WARNING!
The busbars inside the cabinet of liquid-cooled drives are partially coated.
Measurements made through the coating are potentially unreliable, so only
measure at uncoated portions. Note that the coating does not constitute a safe
or touch-proof insulation.
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
3

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
This manual is applicable to ACS880-07CLC drives which have the option: Emergency stop,
stop category 0 with main contactor/breaker, with safety relays (option +Q951).
This manual shows the default design of the safety circuit ordered with option code +Q951.
The actual design can be different from the default design because of customer-defined
modifications. Always refer to the documentation delivered with the drive.
Target audience
This manual is intended for people who install, commission, 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.
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.
2
Introduction to the manual 11

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 validation test to make sure that the implemented system meets the safety requirements. You
can find the instructions for the validation test in this manual.
Document the validation test procedure. You can find the guidelines for the validation test report in this
manual.
Related documents
CodeName
Drive hardware
3AXD50000131457ACS880-07CLC 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
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
www.abb.com/safetyABB Safety information and solutions
Options
3AXD50000709830Emergency stop, stop category 0 (option +Q951) for ACS880-07CLC drives user's
manual
3AUA0000085685ACX-AP-x assistant control panels user's manual
Other documents
Delivered with the driveCircuit diagrams
Delivered with the drivePart lists
Safety data report (if ordered with option +P947)
You can find manuals and other product documents in PDF format on the Internet at
www.abb.com/drives/documents.
12 Introduction to the manual

ACS880-07CLC manuals
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
Control board built in a housing (often rail-mountable)Control unit
Diagnostic coverage (EN ISO 13849-1)DC
Digital inputDI
Digital input interlockDIIL
Frequency converter for controlling AC motorsDrive
Emergency stopE-stop
Physical size of the drive or power moduleFrame, frame size
Hardware fault tolerance (IEC 61508)HFT
Inverter module(s) under control of one control unit, and related components. One
inverter unit typically controls one motor.
Inverter unit
Average probability of dangerous failure on demand (IEC 61508)PFDavg
Average frequency of dangerous failures per hour (IEC 61508)PFH
Performance level. Levels a...e correspond to SIL (EN ISO 13849-1)PL
Periodic test performed to detect failures in a safety-related system so that, if neces-
sary, a repair can restore the system to an “as new” condition or as close as practical
to this condition. (IEC 61508, IEC 62061)
Proof test
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
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
Introduction to the manual 13

DescriptionTerm
Mission time: the period of time covering the intended use of the safety function/device.
After the mission time elapses, the safety device must be replaced. Note that any TM
values given cannot be regarded as a guarantee or warranty. (EN ISO 13849-1)
TM
Confirmation by, for example, analysis that the safety system meets the functional
safety requirements of the specific application.
Validation
Confirmation by, for example, testing that the safety system meets the requirements
set by the specification.
Verification
14 Introduction to the manual

Option description
Contents of this chapter
This chapter describes the +Q951 emergency stop option and its settings.
Overview
Option +Q951 corresponds to an uncontrolled stop in accordance with stop category 0
(IEC/EN 60204-1). When the user gives the emergency stop command, the drive opens
the main contactor/breaker, which disconnects the input power from the drive. The motor
coasts to a stop.
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.
The design principles of the option +Q951 comply with EN ISO 13850.
For a list of related standards and European directives, see section Related standards and
directives (page 37).
Operation principle
The figure shows a simplified operation principle. The user is responsible for the installation
of the main contactor/breaker and its control and monitoring circuits. Also, the implementation
3
Option description 15

of the charging circuit can be different than shown in the figure. For a detailed description,
refer to the circuit diagrams delivered with the drive.
-S61-S61
-K640-K640
-A41 -T11.x
XSTO XSTO
.OUT 2)
IN2
IN1
SGND
OUT
OUT1
SGND
OUT2
SGND
-X52B -X51B
IN1
SGND
IN2
SGND
OUT1
SGND
OUT2
SGND
-A41 -T11.x
XSTO XSTO
.OUT 2)
IN2
IN1
SGND
OUT
OUT1
SGND
OUT2
SGND
-X52B -X51B
IN1
SGND
IN2
SGND
OUT1
SGND
OUT2
SGND
-A640-A640
-A51
DIIL
24 VDC
-A51
DIIL
24 VDC
-A640
-A51
DIIL
24 VDC
-K640-K640
-Q4-Q4
230 VAC
-K640-K640
-Qx-Qx
1)
-A640
-S62-S62
+24 VDC
-Qx
~
-T01
-Q4
~~
-T11
M
3~
M
3~
~
-T11
M
3~
-Qx
~
-T01
-Q4
~
-T11
M
3~
-S62-S62
-Q4-Q4
QxQx
3)
The dashed line in the figure shows a user-defined installation.- - -
Inverter control unitA41
Supply control unitA51
Emergency stop safety relayA640
Safety relayK640
Emergency stop buttonS61
Emergency stop reset button with indicator lightS62
Main contactor/breaker (user-defined)Qx
Charging contactor (option +F272)Q4
Supply unitT01
Inverter unit which contains inverter module(s)T11
Inverter moduleT11.x
Supply voltage for main contactor/breaker control (user-defined)1)
Connection to parallel inverter modules (if any)2)
Main circuit3)
OperationStep
Initial status: The drive is in operation and the motor is running.
The user pushes the emergency stop button [S61]. This activates the emergency stop function.1
The emergency stop safety relay [A640] de-energizes XSTO inputs IN1 and IN2 of the inverter
control unit [A41]. This activates the inverter unit Safe torque off function.
2
The emergency stop safety relay [A640] de-energizes the DIIL input on the supply control unit [A51].
This gives the emergency stop command to the supply unit.
The emergency stop safety relay [A640] de-energizes the safety relay [K640].
The safety relay [K640] opens the main contactor/breaker [Qx], which disconnects the input power
from the supply unit [T01].
The charging contactor [Q4] is opened, if the emergency stop is activated during charging.
16 Option description

OperationStep
The emergency stop reset button indicator light [S62] comes on.3
The motor coasts to a stop.4
Normal operation resumes after the user:5
•releases the emergency stop button [S61] to the normal (up) position
•pushes the emergency stop reset button [S62] for 0.1 … 3 seconds
•resets the faults from the drive (if the drive tripped on a fault)
•makes sure that the drive receives the start signal (depends on the configuration, see the firmware
manual).
Fault reaction function
Definition: A safety function requires a “fault reaction function” that tries to initiate a safe
state if it detects a failure in the safety system.
The fault reaction function of the emergency stop safety relay trips the system, if it detects
a failure in the safety circuit (for example, short circuit between signals, open circuit, or
redundancy fault).
If a fault is detected, the fault reaction function:
•activates the emergency stop command
•activates the drive STO function
•opens the main contactor/breaker
•keeps the safe state activated and the emergency stop reset button indicator light on
until the fault is repaired and the safety function is reset.
Note: Resetting the safety function is not possible, if the reset circuit in the emergency stop
safety relay is open.
Hardware settings
The hardware settings for the safety function are set at the factory.
The emergency stop safety relay [A640] is set to the manual reset mode at the factory. Do
not change this setting.
For more information, see the circuit diagrams delivered with the drive.
Option description 17

18

Electrical installation
Contents of this chapter
This chapter describes the wiring of the safety option done at the factory and contains
guidelines for making user connections.
Wiring
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.
One emergency stop button is installed on the cabinet door and connected to the emergency
stop safety relay [A640] at the factory. There are double contacts in the emergency stop
button and double wiring (two-channel connection) between the button and the emergency
stop safety relay. The emergency stop safety relay [A640] detects cross faults and faults
across one contact from the emergency stop button.
The drive does not have a factory-installed main contactor/breaker. You must install one
and connect its control circuit and status monitoring circuit to the drive. Refer to the drive
hardware manual and the circuit diagrams delivered with the drive.
Note: The safety system and all user-made connections are on the user's responsibility.
4
Electrical installation 19
11

20