ABB +Q957 User manual

—
OPTIONS FOR ABB DRIVES
Prevention of unexpected start-up (option
+Q957) for
ACS880-07/07LC/17/17LC/37/37LC drives
User's manual

Prevention of unexpected start-up
(option +Q957) 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
3AUA0000119910 Rev H
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 ....................................................................................
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 .............................................................................
17Hardware settings ..................................................................................
4 Electrical installation
19Contents of this chapter ...........................................................................
19Wiring ................................................................................................
5 Parameter settings
21Contents of this chapter ...........................................................................
21Drive parameter settings ..........................................................................
21
Additional parameter settings for ACS880-07/07LC drives, frames n×DXT + n×R8i and
ACS880-17/17LC/37/37LC drives, frames n×R8i + n×R8i ...................................
6 Use of the safety function
23Contents of this chapter ...........................................................................
23Activating the safety function .....................................................................
23Resetting the safety function .....................................................................
7 Start-up and validation test
25Contents of this chapter ...........................................................................
25Validation of the safety functions ................................................................
25Competence .....................................................................................
25Validation procedure ...........................................................................
26Validation test reports ..........................................................................
26Start-up and validation test .......................................................................
Table of contents 5

8 Fault tracing
29Contents of this chapter ...........................................................................
29Fault tracing .........................................................................................
30Reporting problems and failures related to safety functions .................................
9 Maintenance
31Contents of this chapter ...........................................................................
31Safety circuit maintenance .......................................................................
31Proof test interval ..................................................................................
32Competence ........................................................................................
32Residual risk ........................................................................................
32Intentional misuse ..................................................................................
32Decommissioning ..................................................................................
10 Technical data
33Contents of this chapter ...........................................................................
33Safety data ..........................................................................................
33Safety data values ..............................................................................
34Safety component types .......................................................................
34Safety block diagrams .........................................................................
34Relevant failure modes ........................................................................
34Fault exclusions ................................................................................
34Operation delays ...............................................................................
35Ambient conditions ................................................................................
35ACS880-07 drives, frames R6…R11 ........................................................
35Related standards and directives ................................................................
36Compliance 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: Prevention of unexpected start-up (option +Q957).
This manual shows the default design of the safety circuit ordered with option code +Q957.
The actual design can be different from the default design because of customer-defined
modifications. Always refer to the documentation delivered with the drive.
Target audience
This manual is intended for people who install, commission, use and service the safety
function. Read the manual before working on the unit. You are expected to know the
fundamentals of electricity, wiring, electrical components, electrical schematic symbols, and
functional safety.
Exclusion of liability
ABB is not responsible for the implementation, verification and validation of the overall safety
system. It is the responsibility of the system integrator (or other party) who is responsible
for the overall system and system safety.
The system integrator (or other responsible party) must make sure that the entire
implementation complies with the instructions in this manual, all relevant standards, directives
and local electrical code, and that the system is tested, verified and validated correctly.
2
Introduction to the manual 11

Quick reference guide for taking a safety function into use
Task
Connect the user-defined wiring (if any). See the wiring instructions in this manual and the circuit dia-
grams delivered with the drive.
Check and/or set the safety function related parameters (as listed in this manual).
Do the validation test to make sure that the implemented system meets the safety requirements. You
can find the instructions for the validation test in this manual.
Document the validation test procedure. You can find the guidelines for the validation test report in this
manual.
Related 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
Options
3AUA0000085685ACX-AP-x assistant control panels user’s manual
Other documents
Delivered with the driveCircuit diagrams
Delivered with the drivePart lists
Safety data report (if the safety circuit is different from the default design)
See www.abb.com/drives/documents for all manuals on the Internet.
12 Introduction to the manual

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
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
Frame size designation of the diode supply moduleD8T
Diagnostic coverage (EN ISO 13849-1)DC
Failure in time: 1E-9 hours (IEC 61508)FIT
Physical size of the drive or power moduleFrame, frame size
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
Introduction to the manual 13

DescriptionTerm
Performance level. Levels a...e correspond to SIL (EN ISO 13849-1)PL
Prevention of unexpected start-upPOUS
Systematic capability (IEC 61508)SC
Safety integrity level (1...3) (IEC 61508)SIL
Maximum SIL (level 1...3) that can be claimed for a safety function or subsystem
(IEC/EN 62061)
SILCL
Safe torque off (IEC/EN 61800-5-2)STO
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
14 Introduction to the manual

Option description
Contents of this chapter
This chapter describes the option +Q957, prevention of unexpected start-up, and its settings.
Overview
The option +Q957 uses a safety relay to implement the Prevention of unexpected start-up
(POUS) safety function. ABB installs the safety relay to the drive at the factory.
The user must install and connect an operating switch and an indication lamp (optional) on
site. These are not included in the delivery. The user can install the operating switch on, for
example, a control desk. See the machine-specific C-type standards on whether the indication
lamp is required.
When the user sets the operating switch to the open position, the POUS function activates
the Safe torque off (STO) function in the drive. The Safe torque off function disables the
control voltage of the power semiconductors of the drive output stage. This prevents the
drive from generating the torque required to rotate the motor. With the POUS function, the
user can do short-time operations (like cleaning) or maintenance work on the non-electrical
parts of the machinery without switching off and disconnecting the drive.
Note: The situations in which you can use the POUS function must always be based on a
risk assessment. Refer to IEC 60204-1:2016.
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 drive STO function immediately
and the motor coasts to a stop. For more information on the emergency stop function, see
the applicable user's manual.
3
Option description 15

Note: ACS880-07/07LC drives, frames n×DXT + n×R8i with a main contactor/breaker (option
+F250/+F255), ACS880-17/17LC/37/37LC drives, frames n×R8i + n×R8i, and ACS880-17/37
drives, frames R8 and R11: When the inverter unit STO is activated, the main
contactor/breaker is opened after a user-defined delay (defined with parameter 94.11, the
default value is 600 s). See the hardware and firmware manuals for more information.
For a detailed description of the drive STO function, see the hardware manual.
The design principles of the option +Q957 comply with EN ISO 14118. The STO function
complies with IEC/EN 61800-5-2. For a complete list of related standards and European
directives, see section Related standards and directives (page 35).
Operation principle
The figure shows a simplified operation principle. For a more detailed description, refer to
the circuit diagrams delivered with the drive.
-A65
24 VDC+
1
0
-P
-A41-T11.x
XSTO
XSTO
.OUT 2)
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
-X96 9-X96 9
1)
-S
M
3~
M
3~
~~
3)
Main ci rcu it
~
M
3~
~
3)
Main ci rcu it
~
The dashed line in the figure shows a user-defined installation.- - -
Inverter control unitA41
POUS safety relayA65
POUS switch (user-defined)S
POUS indicator lamp (user-defined)P
Inverter module(s) under inverter unit T11 (only for R8i)T11.x
STO terminal blockX969
Reset (automatic)1)
To parallel inverter modules (if any)2)
Drive module3)
OperationStep
Initial status: The drive is in operation, but the motor is not running.
The user sets the POUS switch [S] to the open position. This activates the POUS function.1
The POUS safety relay [A65] de-energizes the XSTO inputs IN1 and IN2 of the inverter control unit
[A41], which activates the drive STO function. The drive shows an indication.
2
The POUS indication lamp [P] comes on.3
16 Option description

OperationStep
The user cannot start the motor while the drive STO is active.4
Normal operation resumes after the user:5
•sets the POUS switch [S] to the closed position
•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).
Fault reaction function
Definition: A safety function requires a “fault reaction function” that tries to initiate a safe
state if it detects a failure in the safety system.
The fault reaction function of the POUS safety relay trips the system, if it detects a failure
in the safety circuit (for example, short circuit between signals, open circuit, or redundancy
fault).
If a fault is detected, the fault reaction function:
• activates the POUS request
• activates the drive STO function
• keeps the safe state activated and the POUS indication lamp on until the fault is repaired
and the safety function is reset.
The STO function has its own internal fault diagnostics and fault reaction function.
Hardware settings
The hardware settings for the safety function are set at the factory.
The settings in the POUS safety relay [A65] are:
•Cross fault detection is set to With
•Start mode is set to Automatic.
Note: If the cross fault detection is set to Without, the fault diagnostics of the wiring
decreases.
For more information, see the circuit diagrams delivered with the drive.
Option description 17

18

Electrical installation
Contents of this chapter
This chapter describes the wiring of the safety option done at the factory and contains
guidelines for making user connections.
Wiring
The operating switch and the indication lamp for the POUS function are not factory-installed.
The user must install and connect them to the drive 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.
Connect the POUS switch to the applicable terminals inside the drive cabinet. For the POUS
indication lamp [P], ABB recommends an LED indication lamp. Refer to the circuit diagrams
delivered with the drive. Obey the rules below:
1. Use only double-contact switches. ABB recommends approved and lockable switches.
2. Connect the switch with two conductors (two-channel connection). Keep the channels
separate.
Note: If you use only one channel in a two-channel implementation, or if the channels
are connected together, the cross fault detection of the POUS relay detects a redundancy
fault and activates the fault reaction function.
Note: The safety circuit design can be different when modified according to the customer's
safety requirements. Refer to the circuit diagrams delivered with the drive.
3. Use shielded, twisted pair cables. ABB recommends double-shielded cable and
gold-plated contacts in the POUS switch.
4
Electrical installation 19
11

4. Make sure that the sum resistance for one channel (loop resistance) is not more than 70
ohms.
5. Obey the general control cable installation instructions given in the drive hardware manual.
20 Electrical installation