ABB ACS880 Series User manual

—
OPTIONS FOR ABB DRIVES
Safely-limited speed with the encoder
interface (option +Q965) for
ACS880-07/07LC/17/17LC/37/37LC drives
User's manual

Safely-limited speed with the encoder
interface (option +Q965) 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 validation test
3AXD50000019727 Rev F
EN
EFFECTIVE: 2020-09-30

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 ....................................................................................
12Exclusion of liability ................................................................................
12Quick reference guide for taking a safety function into use ..................................
12Related manuals ...................................................................................
14Terms and abbreviations ..........................................................................
3 Option description
15Contents of this chapter ...........................................................................
15Overview ............................................................................................
16Summary of wirings and settings ............................................................
17Operation principle .................................................................................
17SLS function .....................................................................................
18SLS with speed below the monitored speed ............................................
20SLS with speed above the monitored speed - time monitoring ......................
22SLS with speed above the monitored speed - ramp monitoring .....................
23SLS reaction when modulation is lost during deceleration ramp ....................
28SMS function ....................................................................................
29SSM function ....................................................................................
30Drive modulation loss when encoder feedback is used ..................................
31Operation principle diagram ..................................................................
32Fault reaction function .............................................................................
32FSO module .....................................................................................
32Resetting the FSO module ................................................................
32FSE-31 module and safety encoder .........................................................
33Drive STO function .............................................................................
4 Electrical installation
35Contents of this chapter ...........................................................................
35Wiring ................................................................................................
36SLS function .....................................................................................
36SMS function ....................................................................................
36SSM function ....................................................................................
5 Parameter settings
37Contents of this chapter ...........................................................................
Table of contents 5

37Competence ........................................................................................
37FSO module parameter settings .................................................................
38General parameters ............................................................................
39Parameters for the STO function .............................................................
40Parameters for the SSE function .............................................................
43Parameters for the SLS function .............................................................
46Parameters for the SMS function ............................................................
46Parameters for the SSM function ............................................................
47FSE-31 module and safety pulse encoder related parameters ..........................
49Drive parameter settings ..........................................................................
49Ramp parameters ..................................................................................
6 Use of the safety function
51Contents of this chapter ...........................................................................
51Activating and deactivating the SLS function ..................................................
51Activating and deactivating the SMS function .................................................
52Activating and deactivating the SSM function .................................................
7 Start-up and validation test
53Contents of this chapter ...........................................................................
53Validation of the safety functions ................................................................
53Competence .....................................................................................
53Validation procedure ...........................................................................
54Validation test reports ..........................................................................
54Start-up and validation test .......................................................................
8 Maintenance
59Contents of this chapter ...........................................................................
59Safety circuit maintenance .......................................................................
59Proof test interval ..................................................................................
60Competence ........................................................................................
60Residual risk ........................................................................................
60Intentional misuse ..................................................................................
60Decommissioning ..................................................................................
9 Technical data
61Contents of this chapter ...........................................................................
61Safety data ..........................................................................................
61Safety performance with different safety pulse encoders ................................
62Safety data values ..............................................................................
62Safety component types .......................................................................
62Safety block diagrams .........................................................................
63Relevant failure modes ........................................................................
63Fault exclusions ................................................................................
63Operation delays ...............................................................................
63Ambient conditions ................................................................................
63Related standards and directives ................................................................
64Compliance 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 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 9).
WARNING!
(With permanent magnet or synchronous reluctance [SynRM] motors only)
In case of a multiple IGBT power semiconductor failure, the drive system 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. p
denotes the number of pole pairs.
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.
• 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.
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.
• 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.
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 9

10

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 ACS880-07/07LC/17/17LC/37/37LC drives which have the
option +Q965: Safely-limited speed (SLS) with encoder, with FSO-21 and FSE-31.
Required versions when using the FSO-21 module with option +Q965:
• 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
• Drive composer pro: 1.8 or later.
The FSO-21 module safety functionality described in this manual is valid for revision H. For
earlier FSO module revisions, not all functionality related to the SLS function is supported.
This manual shows the default design of the safety circuit ordered with option code +Q965.
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.
2
Introduction to the manual 11

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 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 and in the FSO module user's manual.
Document the validation test procedure. You can find the guidelines for the validation test report in this
manual and in the FSO module user's 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
www.abb.com/safetyABB Safety information and solutions
12 Introduction to the manual

CodeManual
Options
3AUA0000085685ACX-AP-x assistant control panels user’s manual
3AXD50000015614FSO-21 safety functions module user’s manual
3AXD50000016597FSE-31 pulse encoder interface module user’s manual
Other documents
Delivered with the driveCircuit diagrams
Delivered with the drivePart lists
Safety data report (if the safety circuit is different from the default design)
See www.abb.com/drives/documents for all manuals on the Internet.
ACS880-07LC manualsACS880-07 (560 to 2800 kW)
manuals
ACS880-07 (45 to 710 kW) manuals
ACS880-17LC manualsACS880-17 (160 to 3200 kW)
manuals
ACS880-17 (45 to 400 kW) manuals
ACS880-37LC manualsACS880-37 (160 to 3200 kW)
manuals
ACS880-37 (45 to 400 kW) manuals
Introduction to the manual 13

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
Diagnostic coverage (EN ISO 13849-1)DC
Physical size of the drive or power moduleFrame, frame size
Optional pulse encoder interface module for safety encoderFSE-31
Safety functions module which supports the FSE-31 module and the use of safety
encoders
FSO-21
Hardware fault tolerance (IEC 61508)HFT
Insulated gate bipolar transistorIGBT
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
Programmable logic controllerPLC
Prevention of unexpected start-upPOUS
Worst case elapsed time following an actuation of a safety sensor connected to a
fieldbus before the corresponding safe state of its safety actuator(s) is achieved in
the presence of errors or failures in the safety function channel.
Safety function re-
sponse time
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
The speed limit at which SLS monitoring is started, located in the middle of SLS trip
limit and SLS limit.
SLS monitoring limit
Safe maximum speedSMS
Safe stop 1 (IEC/EN 61800-5-2)SS1
Safe stop emergencySSE
Safe speed monitor without encoderSSM
Safe torque off (IEC/EN 61800-5-2)STO
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
For safety functions, the zero speed limit indicates the completion of the safe stopping
function.
Zero speed
14 Introduction to the manual

Option description
Contents of this chapter
This chapter describes the operation of the option +Q965, Safely-limited speed with the
encoder interface, and its settings.
Overview
Option +Q965 uses the FSO-21 safety functions module (option +Q972) and the FSE-31
pulse encoder interface module (option +L521). ABB installs the FSO-21 and FSE-31
modules to the drive and sets the delivery configuration for the option at the factory.
With option +Q965, these safety functions are configured in the FSO module at the factory:
• Safely-limited speed (SLS). This function prevents the motor speed from exceeding the
user-defined speed limits.
• Safe maximum speed (SMS). This function prevents the machine from exceeding the
user-defined maximum speed of the machine or process.
• Safe speed monitor (SSM). This function provides a safe output signal to indicate when
the motor speed is between user-defined limits.
The user defines the operation of the SLS, SMS and SSM functions with the FSO module
parameters at the start-up, for example, by setting the speed limits.
Note: If the Safe brake control (SBC) function is used, it is also activated according to the
configuration (either before or after the drive STO function is activated, or at a specified
speed limit). In this case, make sure that you have dimensioned the brake correctly for these
situations. For more information, see the FSO module user’s manual.
To maintain the SIL/PL capability, the motor must be equipped with a safety encoder.
Note: A safety function request to the FSO module must be active for a minimum of 20 ms.
3
Option description 15

Note: Motor thermal protection options (options +L513/+L514+Q971, +L536, or +L537+Q971)
use the same digital input as the default design of option +Q965. If you have both options
in the same drive, option +Q965 will use an alternative digital input. Refer to the
delivery-specific circuit diagrams.
For more information on the safety functions of the FSO module, see 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 SLS and SSM functions comply with IEC/EN 61800-5-2. The SMS function is a special
implementation of the SLS function. For a complete list of related standards and European
directives, see section Related standards and directives (page 63).
￭Summary of wirings and settings
General information:
• The drive is equipped with the FSO-21 safety functions module (option +Q972). ABB
installs the module at the factory.
• 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 encoder. The user installs the safety encoder
and connects it 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.
The wirings and settings of the SLS function are:
• The user connects the SLS activation signal (for example, a switch) to the FSO module.
• The user connects the SLS indication signal (for example, an indication lamp or a gate
opening signal) to the FSO module.
• The digital input of the FSO module to which the SLS activation signal is connected, is
selected as the input for the SLS request. ABB sets the safety IO settings for SLS input
and output at the factory to agree with the circuit diagrams.
• The digital output of the FSO module to which the SLS indication signal is connected, is
selected as the SLS output. ABB sets the safety IO settings for SLS input and output at
the factory to agree with the circuit diagrams.
• The speed limits must be set according to the application requirements.
• The SLS function is set to use either the time monitoring or ramp monitoring method to
monitor the deceleration of the motor to the SLS speed limit.
• The deceleration time and limits for the deceleration ramp activated by the SLS function
are set according to the application requirements.
The wirings and settings of the SMS function are:
• There are two different versions of the SMS function. Version 1 monitors the motor speed
and trips the drive if the user-defined trip limit is exceeded. Version 2 of the SMS function
is similar to the SLS function except that it can only be configured to be continuously on
or off. ABB activates the SMS function (Version 1) at the factory.
• The SMS positive and negative speed limits are FSO module parameters that the user
must set at the start-up.
16 Option description

The wirings and settings of the SSM function are:
• ABB configures the SSM function at the factory to be permanently active. The user can
change this setting with FSO module parameters.
• The user wires the SSM indication signal (for example, an indication lamp) to the FSO
module.
• ABB sets the safety IO settings for the SSM output at the factory to agree with the circuit
diagrams.
• The SSM positive and negative speed limits are FSO module parameters that the user
must set at the start-up.
Operation principle
￭SLS function
The SLS function limits the motor speed so that it does not exceed the user-defined speed
limits when the function is active. The user defines the SLS limits and trip limits at the
start-up. When the user activates the SLS function, the FSO module sends a SLS request
to the drive . The drive takes the SLS parameters into use and controls the motor speed
accordingly until the user deactivates the SLS request.
If the motor speed is above the user-defined SLS trip limit when the SLS function is activated,
the drive first decelerates the motor speed to the SLS limit. The FSO module monitors the
deceleration to the required speed with the time or ramp monitoring method.
Note: It is a good practice to define the motor speed reference so that it stays between the
SLS limits in the operating situations when the SLS function is active.
If the motor speed reaches the user-defined SLS trip limit, the FSO module activates the
Safe stop emergency (SSE) function. Depending on parameter settings, the SSE function
activates the drive Safe torque off (STO) immediately, or after a deceleration ramp. The
motor coasts to a stop, or decelerates to zero speed.
There are four separate SLS functions in the FSO module with different parameter settings.
In the examples below, and in the delivered default settings of the +Q965 option, the SLS1
function is used.
For more information, see chapter Parameter settings and the FSO module user's manual.
Option description 17

SLS with speed below the monitored speed
This time scheme diagram illustrates the operation of the SLS function. The motor speed
is below the monitored speed when the user activates the SLS function.
1 2 3
SLS request
SLS status &
indication
A
B
C
Motor speed
Time
2b 3b
D
Safety function response timeA
SLS1 limit positive (parameter 200.23)
B
SLS1 trip limit positive (parameter SLSx.14)
C
Zero speed with encoder (parameter FSOGEN.52). Relevant only if 2b occurs.
D
18 Option description

1. The user or a PLC de-energizes the applicable digital inputs of the FSO module. This
activates the SLS request.
2. After the safety function response time (A), the FSO module starts to monitor the motor
speed. The FSO module energizes the digital output that indicates the SLS status.
While the monitoring is active, the drive limits the motor speed so that it stays at or below
the SLS1 limit positive. The FSO module monitors the actual motor speed.
(2b) If the motor speed goes above the SLS1 trip limit positive (C), the FSO module
activates the SSE function and the motor coasts to a stop (in this case, the SSE function
has been configured as Immediate STO, see section Parameters for the SSE
function (page 40)).
Note: In this case, the FSO activates the SLS indication when the motor speed goes
below the SLS1 limit positive (B).
Note: In option +Q978, the SBC function is used to control the main contactor/breaker.
If the drive has this option and a trip limit hit occurs, STO activation causes the main
contactor/breaker to open.
3. The user or a PLC energizes the applicable digital inputs of the FSO module. This
deactivates the SLS request. The FSO module acknowledges the SLS1 function
automatically. This is set by an FSO parameter (SLSx.02), and no external
acknowledgement input is used. The FSO module stops SLS monitoring and de-energizes
the SLS indication signal.
(3b) The motor speed goes below the zero speed limit (D). If the FSO module activated
the SSE function at 2b, the STO acknowledgement is now permitted. The user must
reset the drive if the STO indication parameter (FSOGEN.62 or 31.22) is set so that a
fault is generated.
Option description 19

SLS with speed above the monitored speed - time monitoring
This time scheme diagram illustrates the operation of the SLS function with time monitoring.
The motor speed is above the monitored speed when the SLS function is activated.
1 2 3 4
SLS request
SLS status &
indication
5
A
B
3b
C
D
Motor speed
Time
SLSx.04
Safety function response timeA
SLS time delay (parameter SLSx.04): When time B has elapsed from the start of the counter
(step 1 below), the FSO module starts SLS monitoring (if not already started).
B
SLS1 limit positive (parameter 200.23)
C
SLS1 trip limit positive (parameter SLSx.14)
D
1. The user or a PLC de-energizes the applicable digital inputs of the FSO module. This
activates the SLS request. The FSO module starts a counter for time (B).
2. After the safety function response time (A), the drive starts to decelerate the motor
according to the user-defined deceleration ramp. The FSO module starts SLS monitoring
and energizes the digital output that indicates the SLS status when the motor speed is
in the middle of the SLS1 trip limit and the SLS1 limit.
20 Option description