ABB ACS880 Series User manual

—
OPTIONS FOR ABB DRIVES
Prevention of unexpected start-up (option
+Q957) for ACS880 multidrives
User's manual

Prevention of unexpected start-up
(option +Q957) for ACS880
multidrives
User's manual
Table of contents
1. Safety instructions
4. Electrical installation
6. Start-up and acceptance test
© 2019 ABB Oy. All Rights Reserved. 3AUA0000119894 Rev F
EN
EFFECTIVE: 2019-09-19

Table of contents
1 Safety instructions
7Contents of this chapter ..........................................................................
7Use of warnings and notes ......................................................................
7Instructions for functional safety circuits .......................................................
8Electrical 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 manuals ..................................................................................
13Terms and abbreviations .........................................................................
3 Option description
15Contents of this chapter ..........................................................................
15Overview ...........................................................................................
16Operation principle ................................................................................
17Fault reaction function ............................................................................
17Parameter settings ................................................................................
17Inverter unit parameter settings .............................................................
17Hardware settings ................................................................................
4 Electrical installation
19Contents of this chapter ..........................................................................
19Wiring ...............................................................................................
5 Use of the safety function
21Contents of this chapter ..........................................................................
21Activating the safety function ....................................................................
21Resetting the safety function ....................................................................
6 Start-up and acceptance test
23Contents of this chapter ..........................................................................
23Validation of the safety functions ...............................................................
23Competence ...................................................................................
23Validation procedure ..........................................................................
24Acceptance test reports ......................................................................
24Start-up and acceptance test ...................................................................
7 Fault tracing
27Contents of this chapter ..........................................................................
27Fault tracing .......................................................................................
Table of contents 5

27Reporting problems and failures related to safety functions ................................
8 Maintenance
29Contents of this chapter ..........................................................................
29Safety circuit maintenance ......................................................................
29Proof test interval .................................................................................
30Competence .......................................................................................
30Residual risk .......................................................................................
30Intentional misuse ................................................................................
30Decommissioning .................................................................................
9 Technical data
31Contents of this chapter ..........................................................................
31Safety data .........................................................................................
31Safety data values ............................................................................
31Safety component types ......................................................................
31Safety block diagrams ........................................................................
31Relevant failure modes .......................................................................
32Fault exclusions ...............................................................................
32Operation delays ..............................................................................
32Ambient conditions ...............................................................................
32Related standards and directives ...............................................................
33Compliance 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.
Instructions for functional safety circuits
This manual does not repeat the complete safety instructions of the drive but only includes
the instructions related to the scope of this manual.
1
Safety instructions 7

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. All user-made
changes are on the user's responsibility.
WARNING! This safety function does not disconnect the voltage of the main and
auxiliary circuits from the drive. Do not work on the electrical parts of the drive or
the motor before you have isolated the drive system from all power supplies and
made sure by measuring that there is no dangerous voltage present.
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! 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 electrician, 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 the drive is equipped with a DC/DC converter unit (optional): Open the DC
switch/disconnector ([Q11], option +F286) of the DC/DC converter. Open the
disconnecting device of the energy storage connected to the DC/DC converter unit
(outside the drive cabinet).
•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.
8 Safety instructions
3

• Disconnect any 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.
• Use a multimeter with an impedance greater than 1 Mohm.
• Make sure that the voltage between the drive input power terminals (L1, L2, L3)
and the grounding (PE) busbar is close to 0 V.
• Make sure that the voltage between the drive output terminals (T1/U, T2/V, T3/W)
and the grounding (PE) busbar is close to 0 V.
6. 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
The manual applies to ACS880 air-cooled and liquid-cooled multidrives which have the
option: Prevention of unexpected start-up (option +Q957).
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.
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 acceptance test to ensure that the implemented system meets the safety requirements. Instruc-
tions for the acceptance test can be found in this manual.
Document the acceptance test procedure. Guidelines for the acceptance test report can be found in
this manual.
Related manuals
CodeManual
Drive hardware
3AUA0000101764Mechanical installation instructions for ACS880 multidrive cabinets
3AUA0000102324Electrical planning instructions for ACS880 multidrive cabinets and modules
Supply units
3AUA0000130644ACS880-207 IGBT supply units hardware manual
3AUA0000102453ACS880-307 (+A003) diode supply units hardware manual
3AXD50000011408ACS880-307 (+A018) diode supply units hardware manual
3AXD50000020546ACS880-907 regenerative rectifier units hardware manual
Inverter units
3AUA0000102519ACS880-107 inverter units 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
3AXD50000020827ACS880 regenerative rectifier control program firmware manual
PC tools
3AUA0000094606Drive composer start-up and maintenance PC tool user's manual
3AXD10000102417Functional safety design tool user’s manual
Safety
3AUA0000102301Safety instructions for ACS880 multidrive cabinets and modules
3AUA0000048753Functional safety; Technical guide No. 10
1SFC001008B0201Safety and functional safety; A general guide
www.abb.com/safetyABB Safety information and solutions
Options
3AUA0000085685ACX-AP-x assistant control panels 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
12 Introduction to the manual

CodeManual
Safety data report (if the safety circuit is application-engineered)
You can find manuals and other product documents in PDF format on the Internet. See
Document Library. For manuals not available in the Document library, contact your local
ABB representative.
For additional ABB safety information and solutions visit http://www.abb.com/safety.
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.
Hardware fault tolerance (IEC 61508)HFT
Insulated gate bipolar transistorIGBT
Performance level. Levels a...e correspond to SIL (EN ISO 13849-1)PL
Prevention of unexpected start-upPOUS
Safety integrity level (1...3) (IEC 61508)SIL
Safe torque off (IEC/EN 61800-5-2)STO
Introduction to the manual 13

14

Option description
Contents of this chapter
This chapter describes the option +Q957, prevention of unexpected start-up, and its settings.
Overview
The Prevention of unexpected start-up (POUS) function disables the control voltage of the
power semiconductors of the drive (inverter) output stage. This prevents the drive from
generating the torque required to rotate the motor. The POUS function activates the Safe
torque off (STO) function of the drive. By using this function, short-time operations (like
cleaning) and/or maintenance work on the non-electrical parts of the machinery can be
performed without switching off and disconnecting the drive.
The user activates the Prevention of unexpected start-up function using a switch mounted
on a control desk. When the switch is open (off), the POUS function is active and the POUS
indicator lamp is on.
The customer is responsible for installing and connecting the operating switch and the
indicator lamp on site. They are not included in the delivery. See the machine-specific C-type
standards whether the indication lamp is required.
For a detailed description of the Safe torque off function, see the appropriate hardware
manual.
Note: Drives with the Emergency stop, stop category 1 function (option +Q952 or +Q964):
If the user activates the POUS function during the emergency stop deceleration ramp, it
overrides the emergency stop function. This activates the STO function of the drive
immediately and the motor coasts to a stop. For more information on the emergency stop
function, see the appropriate user’s manual.
The design principles of the option +Q957 comply with EN 1037. The STO function complies
with EN/IEC 61800-5-2:2007. For a complete list of related standards and European
directives, see section Related standards and directives.
3
Option description 15

Operation principle
The figure shows a simplified operation principle. For a more detailed description, see the
circuit diagrams delivered with the drive.
-A41 -T11.x
XSTO XSTO
.OUT 6)
IN2
OUT
SGND
IN1
IN2
OUT
SGND
IN1 IN1
SGND
IN2
SNGD
IN1
SGND
IN2
SNGD
-X51B
-X52B
IN1
SGND
IN2
SGND
IN1
SGND
IN2
SGND OUT1
SGND
OUT2
SGND
OUT1
SGND
OUT2
SGND
-A41 -T11.x
XSTO XSTO
.OUT 6)
IN2
OUT
SGND
IN1 IN1
SGND
IN2
SNGD
-X51B
-X52B
IN1
SGND
IN2
SGND OUT1
SGND
OUT2
SGND
-S
1)
-A65
2)
4)
3)
5)
-T22-T22
~
-T22
~
-P
1
0
The dashed line in the figure indicates a user-defined installation.-----
Autoreset1)
Alternative +24 V from supply unit with emergency stops +Q963 and +Q9642)
Alternative +24 V supply for Safe torque off (depending on configuration)3)
Alternative groundings (depending on configuration)4)
To other inverter control units5)
To other parallel R8i modules (if any)6)
POUS switch (user-defined)S
POUS indicator lamp (user-defined)P
POUS safety relayA65
Inverter control unitA41
Main contactor/breaker (Q2 or Q1)Qx
Supply unitT01
Inverter unit(s)T11...Txx
Inverter module(s) under inverter unit T11T11.x
24 V power supplyT22
Initial status: The drive is in operation and the motor is not running.
1. The user activates Prevention of unexpected start-up by switching off the POUS switch
[S].
2. The POUS safety relay [A65] de-energizes the XSTO inputs IN1 and IN2 of the inverter
control units [A41].
16 Option description

The inverter units indicate the status. See section Activating the safety function.
3. The POUS indication lamp [P] switches on.
4. The motors coast to zero speed (if running) and cannot start while STO is on.
5. Normal operation resumes after the user:
• switches on the POUS switch [S]
• resets the inverter units (if the drive tripped on a fault)
• makes sure that the inverter units have received the start signals (depends on the
configuration, see the firmware manual).
Fault reaction function
Definition: A safety function requires a “fault reaction function” that attempts to initiate a
safe state if the safety function's diagnostics detect a fault within the hardware/software that
performs the safety function.
The fault reaction function of the POUS safety relay trips the system if it detects a failure
(short circuit between signals, open circuits, redundancy fault when the POUS switch is
pressed) in the safety circuit consisting of, for example, POUS activation button and the
contacts wired to it.
The fault reaction function shifts the system immediately into safe state by switching on the
POUS command, activating the STO function, and keeping safe state activated and the
POUS indication lamp on until the detected fault has been fixed and safety function has
been reset.
The STO function has its own internal fault diagnostics and fault reaction function.
Parameter settings
￭Inverter unit parameter settings
The parameter setting in ACS880 primary control program:
DescriptionDefault valueNameNo.
Selects which indications are given when one or both Safe
torque off (STO) signals are switched off or lost.
Warning/WarningSTO indication
run/stop
31.22
Warning/Warning is the recommended setting.
Note: ACS880 primary control program controls the inverter unit by default. There are
dedicated control units for the supply and inverter units.
Hardware settings
Appropriate hardware settings have been preset at the factory for the safety function.
The settings in the POUS safety relay [A65] are:
•cross fault detection is set to value On,
•reset is set to value Automatic.
Note: If the cross fault detection is not On, it decreases the fault diagnostics of the wiring.
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 (if any).
Wiring
The operating switch and the indication lamp for the POUS function are not factory-installed.
The user must install and wire them to the inverter units on site.
There are double contacts in the POUS switch [S] and double wiring (redundant two-channel
connection) between the button and the POUS safety relay [A65]. The safety relay detects
cross faults and faults across one contact from the POUS switch.
Wire the POUS switch to the appropriate terminals inside the drive cabinet. For the POUS
indication lamp [P], we recommend an LED indication lamp. See the circuit diagrams
delivered with the drive. Obey the rules below:
1. Use only double-contact switches. We recommend approved and lockable switches.
2. Connect the switch with two conductors (two-channel connection).
Note: Keep the channels separate. Otherwise the cross-fault detection of the POUS
safety relay trips.
3. Use shielded, twisted pair cables. We recommend a double-shielded cable and
gold-plated contacts in the POUS switch.
4. Make sure that the sum resistance for one channel (loop resistance) does not exceed
70 ohms.
5. Obey the general control cable installation instructions given in the inverter unit hardware
manual.
4
Electrical installation 19
11

20