ABB +Q951 User manual

—
OPTIONS FOR ABB INDUSTRIAL DRIVES
Emergency stop functions with button
monitoring (options +Q951+Q984 and
+Q952+Q984) for ACS880 liquid-cooled drives
User's manual

Emergency stop functions with
button monitoring (options
+Q951+Q984 and +Q952+Q984) for
ACS880 liquid-cooled drives
User's manual Table of contents
1. Safety instructions
5. Electrical installation
7. Start-up and validation test
3AXD50000328659 Rev B
EN
Original instructions
EFFECTIVE: 2020-12-28

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 implementing a safety system ....................................
12Related documents ................................................................................
13Terms and abbreviations ..........................................................................
3 Description of option +Q951+Q984
15Contents of this chapter ...........................................................................
15Overview ............................................................................................
16Operation principle .................................................................................
16ACS880-07CLC drives ........................................................................
18ACS880-07LC drives ..........................................................................
20ACS880-17LC/37LC drives ...................................................................
22ACS880 multidrives ............................................................................
23Fault reaction function .............................................................................
24Parameter settings .................................................................................
24ACS880-07CLC/07LC/17LC/37LC drives ..................................................
24ACS880 multidrives ............................................................................
25Hardware settings ..................................................................................
25ACS880-07CLC drives ........................................................................
25ACS880-07LC/17LC/37LC drives and ACS880 multidrives .............................
25Push button monitoring relays ................................................................
4 Description of option +Q952+Q984
27Contents of this chapter ...........................................................................
27Overview ............................................................................................
28Operation principle .................................................................................
28ACS880-07LC drives ..........................................................................
30ACS880-17LC/37LC drives ...................................................................
32ACS880 multidrives ............................................................................
34Fault reaction function .............................................................................
34Parameter settings .................................................................................
34ACS880-07LC/17LC/37LC drives ............................................................
36ACS880 multidrives ............................................................................
37Hardware settings ..................................................................................
37Emergency stop safety relay .................................................................
Table of contents 5

37Push button monitoring relays ................................................................
5 Electrical installation
39Contents of this chapter ...........................................................................
39Wiring ................................................................................................
39Connecting the user-defined push buttons .................................................
40Connecting the push button fault indication ................................................
6 Use of the safety function
41Contents of this chapter ...........................................................................
41Activating the safety function .....................................................................
42Resetting the safety function .....................................................................
7 Start-up and validation test
43Contents of this chapter ...........................................................................
43Validation of the safety functions ................................................................
43Competence .....................................................................................
43Validation procedure ...........................................................................
44Validation test reports ..........................................................................
44Validation test .......................................................................................
8 Fault tracing
47Contents of this chapter ...........................................................................
47General ..............................................................................................
47Emergency stop safety relay .....................................................................
47ACS880-07CLC drives with option +Q951+Q984 .........................................
48ACS880-07LC/17LC/37LC drives and ACS880 multidrives with option +Q951+Q984 .
48ACS880-07LC/17LC/37LC drives and ACS880 multidrives with option +Q952+Q984 .
49Monitoring relays ...................................................................................
9 Maintenance
51Contents of this chapter ...........................................................................
51Safety circuit maintenance .......................................................................
51Proof test ............................................................................................
51Proof test interval ..................................................................................
52Safety components ................................................................................
52Competence ........................................................................................
52Residual risk ........................................................................................
52Intentional misuse ..................................................................................
52Decommissioning ..................................................................................
10 Technical data
53Contents of this chapter ...........................................................................
53Operation delays ...................................................................................
53Mission time ........................................................................................
53Ambient conditions ................................................................................
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 functions described in this manual do 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!
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.)
•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).
•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 liquid-cooled drives which have one of these options:
•Emergency stop, stop category 0 with main contactor/breaker, with safety relays and
push button monitoring (option +Q951+Q984), or
•Emergency stop, stop category 1 with main contactor/breaker, with safety relays and
push button monitoring (option +Q952+Q984).
Note: The contents of this manual are applicable only to drives with push button monitoring
(option +Q984). There are separate manuals for options +Q951 and +Q952, which are not
applicable when combined with option +Q984.
This manual shows the default design of the safety circuit. 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 implementing a safety system
Task
Do a risk assessment according to the relevant standards or regulations, such as ISO 12100.
Select the applicable functional safety standard for the implementation.
Assess safety: analyze and evaluate risks and define risk reduction strategies. Define the safety re-
quirements.
Design the safety system. The part of the design made by ABB is shown in this manual.
Connect the wiring. See the wiring instructions in this manual and the circuit diagrams delivered with
the drive.
Set the parameters related to the safety function (as listed in this manual).
Do the validation test. You can find 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
3AXD50000569786ACS880-07LC drives hardware manual
3AXD50000250295ACS880-17LC drives hardware manual
3AXD50000251407ACS880-37LC drives hardware manual
3AXD50000196111ACS880-107LC inverter units hardware manual
3AXD50000174782ACS880-207LC IGBT supply units hardware manual
3AXD50000579662ACS880-307LC…+A018 diode supply units hardware manual
3AXD50000048634ACS880 liquid-cooled multidrive cabinets and modules electrical planning
3AXD50000048633ACS880 liquid-cooled multidrive cabinets and modules safety instructions
3AXD50000048635ACS880 liquid-cooled multidrive cabinets mechanical installation instructions
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
12 Introduction to the manual

CodeName
Safety
3AUA0000048753Functional safety; Technical guide No. 10
www.abb.com/safetyABB Safety information and solutions
Options
3AXD50000328659Emergency stop functions with button monitoring (options +Q951+Q984 and
+Q952+Q984) for ACS880 liquid-cooled 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
You can find manuals and other product documents in PDF format on the Internet at
www.abb.com/drives/documents.
ACS880-17LC manualsACS880-07LC manualsACS880-07CLC manuals
ACS880-37LC manuals
Terms and abbreviations
DescriptionTerm
Control board built in a housing (often rail-mountable)Control unit
Frequency converter for controlling AC motorsDrive
Converts direct current and voltage to alternating current and voltage.Inverter
Inverter bridge, related components and drive DC link capacitors enclosed in a metal
frame or enclosure. Intended for cabinet installation.
Inverter module
Inverter module(s) under control of one control unit, and related components. One
inverter unit typically controls one motor.
Inverter unit
Drive for controlling several motors which are typically coupled to the same machinery.
Includes one supply unit, and one or several inverter units.
Multidrive
Protective earth (ground)PE
Introduction to the manual 13

DescriptionTerm
Performance level. Levels a...e correspond to SIL (EN ISO 13849-1)PL
Periodic test performed to detect failures in the safety function. The target of the proof
test is to ensure that the safety function still operates correctly and is able to achieve
the safe state. (IEC 61508, IEC 62061)
Proof test
Safety integrity level (1...3) (IEC 61508)SIL
Safe torque off (IEC/EN 61800-5-2)STO
Supply module(s) under control of one control unit, and related components.Supply unit
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

Description of option +Q951+Q984
Contents of this chapter
This chapter contains a description of the safety function. This chapter also shows the
settings related to the safety function.
Overview
The emergency stop function with push button monitoring (option +Q951+Q984) corresponds
to an uncontrolled stop in accordance with stop category 0. This emergency stop function
does not have a SIL/PL classification.
In this emergency stop function, the drive has two different safety circuits:
•the primary safety circuit that consists of the emergency stop button (optional in ACS880
multidrives), the relays, and the contacts wired to them. The emergency stop button
activates the emergency stop function when pushed. Line faults in the primary safety
circuit will cause the emergency stop function to activate.
•the user-implemented push button circuits, which are connected to the push button
monitoring relays. The push buttons activate the emergency stop function when pushed,
but line faults in the push button circuits will not cause the emergency stop function to
activate.
You can connect push buttons to the push button monitoring relays. The push button
monitoring system monitors the status of each button. If there is a fault (for example, a short
circuit or damaged wire) in a push button circuit, the emergency stop function is not activated,
but the main monitoring relay opens a normally-closed relay contact. You can use the relay
contact to implement a fault indication system.
3
Description of option +Q951+Q984 15

When the drive receives the emergency stop command:
1. ACS880-07CLC/07LC/17LC/37LC drives: The drive activates the Safe torque off (STO)
function.
2. The drive opens the main contactor/breaker, which disconnects the input power from
the drive.
3. The motor(s) coast(s) to a stop.
Operation principle
￭ACS880-07CLC drives
-K640-K640
-A41 -T11.x
XSTO XSTO
.OUT 5)
IN2
IN1
SGND
OUT
OUT1
SGND
OUT2
SGND
-X52B -X51B
IN1
SGND
IN2
SGND
OUT1
SGND
OUT2
SGND
-A41 -T11.x
XSTO XSTO
.OUT 5)
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
4)
-A641
1)
BUS
3.1
3.2
-A641
1)
BUS
3.1
3.2
-A640
-S61-S61
-S62-S62
-A64x
R1
R2
BUS
3)
-A64x
R1
R2
BUS
3)
... -S62-S62
QxQx
...
+24 VDC
2)
-A642
R1
R2
BUS
3)
-A642
R1
R2
BUS
3)
-Qx
~
-T01
-Q4
~~
-T11
M
3~
M
3~
~
-T11
M
3~
-Qx
~
-T01
-Q4
~
-T11
M
3~
Q4Q4
6)
User-defined connection- - -
Inverter control unitA41
Supply control unitA51
Emergency stop safety relayA640
Main monitoring relay for the push buttonsA641
Push button monitoring relaysA642 … A64x
Safety relayK640
Main contactor/breaker (user-defined)Qx
Charging contactor (option +F272)Q4
Push button resistorsR1, R2
16 Description of option +Q951+Q984

Emergency stop buttonS61
Emergency stop reset button with indicator lightS62
Supply unitT01
Inverter unit which contains inverter module(s)T11
Inverter moduleT11.x
Relay contact for the push button fault indication signal (for user-defined use). If there is a
fault in a push button circuit, the main monitoring relay opens the relay contact.
1)
Fault signal connection between main monitoring relay and push button monitoring relays2)
User-defined push buttons3)
Supply voltage for main contactor/breaker control (user-defined)4)
Connection to parallel inverter modules (if any)5)
Main circuit6)
OperationStep
Initial status: The drive is in operation and the motor is running.
The user pushes the emergency stop button [S61] or a user-defined push button. 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.
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] or the user-defined button to the normal (up) position
•pushes the emergency reset button [S62] to reset the emergency stop circuit
•resets 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).
Description of option +Q951+Q984 17

￭ACS880-07LC drives
-Qx
~
-T01
~~
-T11
M
3~
M
3~
~
-T11
M
3~
-Qx
~
-T01
~
-T11
M
3~
-K62.1-K62.1
-Qx-Qx
230 VAC
-K62.2-K62.2
-A51
DIIL
24 VDC
-A51
DIIL
24 VDC
-K62.2
-A51
DIIL
24 VDC
-K62.2-K62.2-K62.1-K62.1 -S62-S62
-A61
-S61-S61
-A641
1)
BUS
3.1
3.2
-A641
1)
BUS
3.1
3.2
-A64x
R1
R2
BUS
3)
-A64x
R1
R2
BUS
3)
...
...
2)
-A642
R1
R2
BUS
3)
-A642
R1
R2
BUS
3)
-S62-S62
-A41 -T11.x
XSTO XSTO
.OUT 4)
IN2
IN1
SGND
OUT
OUT1
SGND
OUT2
SGND
-X52B -X51B
IN1
SGND
IN2
SGND
OUT1
SGND
OUT2
SGND
-A41 -T11.x
XSTO XSTO
.OUT 4)
IN2
IN1
SGND
OUT
OUT1
SGND
OUT2
SGND
-X52B -X51B
IN1
SGND
IN2
SGND
OUT1
SGND
OUT2
SGND
-K62.2-K62.2
-X969
-A41 -T11.x
XSTO XSTO
.OUT 4)
IN2
IN1
SGND
OUT
OUT1
SGND
OUT2
SGND
-X52B -X51B
IN1
SGND
IN2
SGND
OUT1
SGND
OUT2
SGND
-K62.2
-X969
+24 VDC
-Qx-Qx
-K62.1-K62.1
5)
User-defined connection- - -
Inverter control unitA41
Supply control unitA51
Emergency stop safety relayA61
Main monitoring relay for the push buttonsA641
Push button monitoring relaysA642 … A64X
Safety relaysK62.1, K62.2
Push button resistorsR1, R2
Main contactor/breakerQx
Emergency stop buttonS61
Emergency stop reset button with indicator lightS62
Supply unitT01
Inverter unit which contains inverter module(s)T11
Inverter moduleT11.x
STO terminal blockX969
Relay contact for the push button fault indication signal (for user-defined use). If there is a
fault in a push button circuit, the main monitoring relay opens the relay contact.
1)
Fault signal connection between main monitoring relay and push button monitoring relays2)
18 Description of option +Q951+Q984

User-defined push buttons3)
Connection to parallel inverter modules (if any)4)
Main circuit5)
OperationStep
Initial status: The drive is in operation and the motor is running.
The user pushes the emergency stop button [S61] or a user-defined push button. This activates the
emergency stop function.
1
The emergency stop safety relay [A61] de-energizes safety relays [K62.1] and [K62.2].2
Safety relay [K62.2] de-energizes XSTO inputs IN1 and IN2 of the inverter control unit [A41]. This ac-
tivates the inverter unit Safe torque off function.
Safety relay [K62.2] de-energizes the DIIL input on the supply control unit [A51]. This gives the emer-
gency stop command to the supply unit.
Safety relay [K62.1] opens the main contactor/breaker [Qx], which disconnects the input power from
the supply unit [T01].
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] or the user-defined button to normal (up) position
•pushes the emergency stop reset button [S62] to reset the emergency stop circuit
•resets 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).
Description of option +Q951+Q984 19

￭ACS880-17LC/37LC drives
-Qx
~
-T01
-Q4
~~
-T11
M
3~
M
3~
~
-T11
M
3~
-Qx
~
-T01
-Q4
~
-T11
M
3~
-K62.2-K62.2
-Q4-Q4
230 VAC
-K62.1-K62.1
-Qx-Qx
230 VAC
-A61-A61
-A51
DIIL
24 VDC
-A51
DIIL
24 VDC
-A61
-A51
DIIL
24 VDC
-K62.2-K62.2-K62.1-K62.1 -S62-S62
-A61
-S61-S61
-A641
1)
BUS
3.1
3.2
-A641
1)
BUS
3.1
3.2
-A64x
R1
R2
BUS
3)
-A64x
R1
R2
BUS
3)
...
...
2)
-A642
R1
R2
BUS
3)
-A642
R1
R2
BUS
3)
-K62.1-K62.1 -S62-S62
-A41 -T11.x
XSTO XSTO
.OUT 4)
IN2
IN1
SGND
OUT
OUT1
SGND
OUT2
SGND
-X52B -X51B
IN1
SGND
IN2
SGND
OUT1
SGND
OUT2
SGND
-A41 -T11.x
XSTO XSTO
.OUT 4)
IN2
IN1
SGND
OUT
OUT1
SGND
OUT2
SGND
-X52B -X51B
IN1
SGND
IN2
SGND
OUT1
SGND
OUT2
SGND
-A61-A61
-X969
-A41 -T11.x
XSTO XSTO
.OUT 4)
IN2
IN1
SGND
OUT
OUT1
SGND
OUT2
SGND
-X52B -X51B
IN1
SGND
IN2
SGND
OUT1
SGND
OUT2
SGND
-A61
-X969
+24 VDC
-Q4-Q4
-K62.2-K62.2
-Qx-Qx
5)
User-defined connection- - -
Inverter control unitA41
Supply control unitA51
Emergency stop safety relayA61
Main monitoring relay for the push buttonsA641
Push button monitoring relaysA642 … A64X
Safety relaysK62.1, K62.2
Push button resistorsR1, R2
Main contactor/breakerQx
Charging contactorQ4
Emergency stop buttonS61
Emergency stop reset button with indicator lightS62
Supply unitT01
Inverter unit which contains inverter module(s)T11
Inverter moduleT11.x
STO terminal blockX969
Relay contact for the push button fault indication signal (for user-defined use). If there is a
fault in a push button circuit, the main monitoring relay opens the relay contact.
1)
20 Description of option +Q951+Q984