ABB ACS880 Series User manual

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

Emergency stop, stop category 0
(option +Q951) 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. 3AUA0000119885 Rev F
EN
EFFECTIVE: 2019-06-28

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
9Contents of this chapter ..........................................................................
9Applicability ........................................................................................
9Target audience ...................................................................................
9Exclusion of liability ...............................................................................
10Quick reference guide for taking a safety function into use ................................
10Related manuals ..................................................................................
11Terms and abbreviations .........................................................................
3 Option description
13Contents of this chapter ..........................................................................
13Overview ...........................................................................................
13Operation principle ................................................................................
15Fault reaction function ............................................................................
15Parameter settings ................................................................................
16Hardware settings ................................................................................
4 Electrical installation
17Contents of this chapter ..........................................................................
17Wiring ...............................................................................................
18Customer-installed main breaker in liquid-cooled ACS880 multidrives ...............
5 Use of the safety function
19Contents of this chapter ..........................................................................
19Activating the safety function ....................................................................
19Resetting the safety function ....................................................................
6 Start-up and acceptance test
21Contents of this chapter ..........................................................................
21Validation of the safety functions ...............................................................
21Competence ...................................................................................
21Validation procedure ..........................................................................
22Acceptance test reports ......................................................................
22Start-up and acceptance test ...................................................................
7 Fault tracing
25Contents of this chapter ..........................................................................
25Fault tracing .......................................................................................
Table of contents 5

25Reporting problems and failures related to safety functions ................................
8 Maintenance
27Contents of this chapter ..........................................................................
27Safety circuit maintenance ......................................................................
27Proof test interval .................................................................................
28Competence .......................................................................................
28Residual risk .......................................................................................
28Intentional misuse ................................................................................
28Decommissioning .................................................................................
9 Technical data
29Contents of this chapter ..........................................................................
29Safety data .........................................................................................
29Safety data values ............................................................................
29Safety component types ......................................................................
29Safety block diagrams ........................................................................
29Relevant failure modes .......................................................................
30Fault exclusions ...............................................................................
30Operation delays ..............................................................................
30Ambient conditions ...............................................................................
30Related standards and directives ...............................................................
31Compliance 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! 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 electrician, 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. 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.
• Make sure that re-connection is not possible. Lock out and tag out.
• 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.
• If you have a permanent magnet motor connected to the drive, 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.
8 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
The manual applies to ACS880 air-cooled and liquid-cooled multidrives which have the
option: Emergency stop, stop category 0 with main contactor/breaker, with safety relays
(option +Q951).
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 9

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
3AUA0000048753Functional safety; Technical guide No. 10 Safety and functional safety; A general guide
1SFC001008B0201Safety and functional safety; A general guide
3AUA0000102301Safety instructions for ACS880 multidrive cabinets and modules
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
drive
Circuit diagrams
10 Introduction to the manual

CodeManual
Delivered with the
drive
Part lists
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.
Digital inputDI
Digital input interlockDIIL
Emergency stopE-stop
Hardware fault tolerance (IEC 61508)HFT
Insulated gate bipolar transistorIGBT
Average frequency of dangerous failures per hour (IEC 61508)PFH
Performance level. Levels a...e correspond to SIL (EN ISO 13849-1)PL
Safety integrity level (1...3) (IEC 61508)SIL
Introduction to the manual 11

12

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
(EN/IEC 60204-1). After the emergency stop command has been given, the drive trips the
main contactor/breaker which cuts off the input power of the drive. The motor(s) coasts to
a stop.
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 30).
Operation principle
The figure shows a simplified operation principle. Implementation of main contactor/breaker
and charging circuit can vary depending on the product. For a more detailed description,
see the circuit diagrams delivered with the drive.
3
Option description 13

-S61 -A61
1)
-T61-T61
~
-T61
~
-K65
-K64
-K66-K66-K65-K65 -K66-K65
DI4 (E-stop)
-A41 2)
-T11.x
XSTO XSTO
.OUT 3)
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
DI4 (E-stop)
-A41 2)
-T11.x
XSTO XSTO
.OUT 3)
IN2
OUT
SGND
IN1 IN1
SGND
IN2
SNGD
-X51B
-X52B
IN1
SGND
IN2
SGND OUT1
SGND
OUT2
SGND
-F61-F61
-K64-K64
-K64-K64 -Qx-Qx
-Q4-Q4
-Qx-Qx -K65-K65
100-250 VAC
-K64 -Qx
-Q4
-Qx -K65
100-250 VAC
-A51
-K66-K66
DIIL
24 VDC
-A51
-K66
DIIL
24 VDC
-S62
-S62-S62
-Q4-Q4
-Qx
~
-T01
...
Main circuit
-Q4
-T11
M
3~
M
3~
-T11
M
3~
-TXX
M
3~
M
3~
-TXX
M
3~
...
-Qx
~
-T01
...
Main circuit
-Q4
-T11
M
3~
-TXX
M
3~
...
-Qx
~
-T01
...
Main circuit
-Q4
-T11
M
3~
-TXX
M
3~
...
~~ ~~
-Qx
~
-T01
...
Main circuit
-Q4
-T11
M
3~
-TXX
M
3~
...
~ ~
The dashed line in the figure indicates a user-defined installation.-----
Inverter control unitA41
Supply control unitA51
Emergency stop safety relay with delay contactsA61
Emergency stop button (user-defined)S61
Emergency stop reset button with indicator light (user-defined)S62
Safety relayK64
Safety relayK65
Safety relayK66
Main contactor/breaker (Q2 or Q1)Qx
Charging contactorQ4
Supply unitT01
Inverter unit(s)T11…Txx
Inverter module(s) under inverter unit T11T11.x
24 V power supplyT61
Circuit protection switchF61
Reset circuit1)
14 Option description

To other inverter control units2)
To parallel inverter modules (if any)3)
Initial status: The drive is in operation and the motor is running.
1. The user activates emergency stop by pushing the emergency stop button [S61].
2. The emergency stop safety relay [A61] switches off the DI input of the inverter control
unit [A41].
The auxiliary relay [K66] switches off the DIIL input of the supply control unit [A51].
The auxiliary safety relay [K65] de-energizes the main contactor/breaker [Qx].
The main contactor/breaker [Qx] switches off the power supply to the supply unit and
inverter units.
3. The emergency stop reset button indicator light [S62] switches on.
4. The motors coast to a stop and remain stopped as long as the emergency stop is active.
5. Normal operation resumes after the user:
• releases the emergency stop button [S61] to normal (up) position
• resets the emergency stop circuit with the emergency stop reset button [S62]
• closes the main contactor/breaker [Qx] with the operating switch
• 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 emergency stop safety relay trips the system if it detects
a failure (short circuit between signals, open circuits, redundancy fault when the emergency
stop button is pressed) in the safety circuit consisting of, for example, emergency stop button
and the contacts wired to it.
The fault reaction function shifts the system immediately into safe state by switching on the
emergency stop command, opening the main contactor/breaker, and keeping safe state
activated and the emergency stop reset button indicator light lit until the detected fault has
been fixed and safety function has been reset.
Note: Resetting the safety function is not possible, if the reset circuit in the emergency stop
safety relay is open.
Parameter settings
Note: ACS880 primary control program controls the inverter unit by default. There are
dedicated control units for the supply and inverter units.
The inverter unit parameter settings in ACS880 primary control program:
•parameter 10.24 RO1 source is set to value P.10.1.3-
•parameter 21.04 Emergency stop mode is set to value Coast stop (Off2)
•parameter 21.05 Emergency stop source is set to value DI4 (delivery-specific, refer
to the circuit diagrams)
Option description 15

•parameter 31.22 STO indication run/stop is set to value Warning/Warning
(recommended).
The supply unit parameter settings in the ACS880 supply control programs:
•parameter 121.04 Emergency stop mode is set to value Stop and warning
•parameter 121.05 Emergency stop source is set to value DIIL.
For more information, see the firmware manuals.
Hardware settings
Appropriate hardware settings have been preset at the factory for the safety function.
The settings in the emergency stop safety relay [A61] are:
•cross fault detection is set to value On,
•manual reset is set to value On.
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.
16 Option description

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
If option +G331 has been selected, one emergency stop button and one reset button are
installed on the cabinet door and wired to the drive at the factory. There are double contacts
in the emergency stop button and double wiring (redundant two-channel connection) between
the button and the emergency stop safety relay [A61]. The safety relay detects cross faults
and faults across one contact from the emergency stop button.
If needed, install additional emergency stop buttons on site and wire them to the appropriate
terminal block inside the drive cabinet. See the circuit diagrams delivered with the drive.
Obey these general rules:
1. Use only double-contact buttons approved for the emergency stop circuits.
2. Connect the emergency stop buttons with two conductors (two-channel connection).
Note: Keep the channels separate. If you use only one channel, or if the first and second
channels are connected together (for example, in a chain), the cross-fault detection of
the emergency stop safety relay trips and activates the emergency stop command of
the inverter unit as it detects a redundancy fault.
3. Use shielded, twisted pair cables. We recommend a double-shielded cable and
gold-plated contacts in the emergency stop button.
4. Ensure that the sum resistance for one channel (loop resistance) does not exceed 70
ohm.
5. Obey the general control cable installation instructions given in the drive hardware
manual.
4
Electrical installation 17
11

You can also install additional reset buttons and indication lamps for the emergency stop
circuit on site. We recommend gold-plated contacts in the reset button. Wire the buttons to
the appropriate terminal block inside the drive cabinet. See the circuit diagrams delivered
with the drive. Obey the rules below:
1. Sum resistance of the external reset circuit may not exceed 70 ohm.
2. Obey the general control cable installation instructions given in the drive hardware
manual.
￭Customer-installed main breaker in liquid-cooled ACS880 multidrives
Liquid-cooled ACS880 multidrives can be delivered without a factory-installed main breaker.
In these cases, customer must install and connect the main breaker to the safety circuit as
described in the circuit diagrams.
18 Electrical installation

Use of the safety function
Contents of this chapter
This chapter describes the use of the safety function with factory default settings.
Activating the safety function
1. Push the emergency stop button [S61]. The emergency stop is activated and the button
locks in the “ON” (open) position.
When the emergency stop is on, the following indications are shown:
•the inverter unit control program has the warning Emergency stop active,
• the emergency stop reset button indicator light [S62] on cabinet door is lit.
Resetting the safety function
1. Turn the emergency stop button [S61] until it releases.
2. Push the emergency stop reset button [S62] on the cabinet door. The emergency stop
reset button indicator light [S62] goes out, the emergency stop is deactivated.
3. Reset the inverter units if necessary.
4. If necessary, close the main contactor with the operating switch (see the hardware and
firmware manuals).
The main contactor/breaker closes and the drive is powered up.
5. Make sure that the inverter units have received the start signal (depends on the
configuration, see the firmware manual).
6. You can now restart the inverter units.
Note: You have to reset the emergency stop circuit with the reset button [S62] also after
you have powered up the drive.
5
Use of the safety function 19

20