ABB DCS8 Series Product information sheet

—
Options for ABB drives
Original user’s manual
Prevention of unexpected start-up (option +Q957)
for DCS8x0-A enclosed converters
equipped with DCS880 modules
Individual drive POUS
E-Stop
cat.0
E-Stop
cat.1
POUS
forced MC
opening
+Q951
x
x
+Q952
x
x
+Q963
x
+Q964
x
+Q957
x

List of related manuals
All the documents available for the drive system DCS880 are listed below:
General
Publication number
EN
DE
IT
ES
FR
PL
ZH
RU
DCS880 Quick guide
3ADW000545
EN
DE
IT
ES
FR
Safety instructions all languages
3ADW000481
EN
DE
IT
ES
FR
PL
ZH
RU
DCS880 Manual set
DCS880
Manual set
EN
DCS880 Units
DCS880 Flyer
3ADW000475
EN
DE
IT
ES
FR
ZH
RU
DCS880 Technical catalog
3ADW000465
EN
DE
IT
ES
FR
PL
ZH
RU
DCS880 Hardware manual
3ADW000462
EN
DE
IT
ES
FR
PL
RU
DCS880 Firmware manual
3ADW000474
EN
IT
ES
FR
PL
RU
DCS880 Service manual
3ADW000488
EN
DCS880 Hardparallel manual
3ADW000530
EN
DCS880 12-pulse manual
3ADW000533
EN
Instructions for mounting the SDCS-CMA-2
3ADW000396
EN
ACS-AP-x assistant control panels user’s manual
3AUA0000085685
EN
DCS Thyristor power converter – Technical guide
3ADW000163
EN
Functional safety
Supplement for functional safety
3ADW000452
EN
IT
ES
FR
PL
RU
Functional safety for enclosed converter
+Q957 Prevention of unexpected Start Up
3ADW000504
EN
+Q951 Emergency stop, category 0 with MC opening
3ADW000505
EN
+Q952 Emergency stop, category 1 with MC opening
3ADW000506
EN
+Q963 Emergency stop, category 0 without MC opening
3ADW000507
EN
+Q964 Emergency stop, category 1 without MC opening
3ADW000508
EN
Enclosed converter
DCS800-A Installation manual
3ADW000352
EN
DE
DCS800-A +S880 Enclosed converters, flyer
3ADW000523
EN
Door mounting kits
DPMP-01 mounting platform for ACS-AP control panel
3AUA0000100140
EN
DPMP-02 mounting platform for ACS-AP control panel
3AUA0000136205
EN
Serial communication
FCAN-01 CANopen adapter module
3AFE68615500
EN
DE
FDNA-01 DeviceNet™ adapter module
3AFE68573360
EN
FECA-01 EtherCAT adapter module
3AUA0000068940
EN
DE
ES
FENA-11/-21 Ethernet adapter module
3AUA0000093568
EN
ZH
FEPL-02 Ethernet POWERLINK adapter module
3AUA0000123527
EN
DE
FPBA-01 PROFIBUS DP adapter module
3AFE68573271
EN
DE
PL
ZH
FSCA-01 RS-485 adapter module
3AUA0000109533
EN
ZH
FDCO-01/02 DDCS communication modules
3AUA0000114058
EN
Tool and maintenance manuals and guides
Drive composer PC tool
3AUA0000094606
EN
Drive application programming (IEC61131-3) manual
3AUA0000127808
EN
Adaptive programming, Application guide
3AXD50000028574
EN
NETA-21 remote monitoring tool
3AUA0000096939
EN
NETA-21 remote monitoring tool guide
3AUA0000096881
EN
DDCS branching unit NDBU-95 user’s manual
3BFE64285513
EN
Extension modules
FIO-11 Analog extension module
3AFE68784930
EN
DE
IT
FIO-01 Digital extension module
3AFE68784921
EN
DE
IT
FAIO-01 Analog extension module
3AUA0000124968
EN
DE
FDIO-01 Digital extension module
3AUA0000124966
EN
FEN-01 TTL encoder interface
3AFE68784603
EN
DE
IT
ZH
FEN-31 HTL encoder interface
3AUA0000031044
EN
ZH
FEA-03 F series extension adapter
3AUA0000115811
EN
Ethernet tool network for ACS880 drives appl. guide
3AUA0000125635
EN
Status 01.2020 DCS880 Manuals list m en.docx

3
Table of contents
3ADW000504R0301 +Q957 Prevention of unexpected start-up en c
Table of contents
List of related manuals 2
Table of contents 3
Safety Instructions 4
Introduction to the manual 5
Contents of this chapter .............................................................................................................................................5
Applicability ....................................................................................................................................................................5
Target audience.............................................................................................................................................................5
Contents..........................................................................................................................................................................5
Related documents.......................................................................................................................................................5
Abbreviations .................................................................................................................................................................6
Exclusion of liability ......................................................................................................................................................6
Quick reference guide for implementing a safety system .................................................................................. 7
Option description and instructions 8
Contents this chapter ..................................................................................................................................................8
+Q957 basic function description .............................................................................................................................8
Operation principle.......................................................................................................................................................9
+Q957 Fault reaction function .................................................................................................................................10
Parameter settings.....................................................................................................................................................10
Hardware settings ...................................................................................................................................................... 11
Wiring ............................................................................................................................................................................. 11
+Q957 Start-up and acceptance test ..................................................................................................................... 12
Use of the safety function......................................................................................................................................... 13
Activating.................................................................................................................................................................. 13
Resetting................................................................................................................................................................... 13
POUS indications......................................................................................................................................................... 13
+Q957 Fault tracing .................................................................................................................................................... 13
+Q957 Maintenance ....................................................................................................................................................14
Proof test interval...................................................................................................................................................14
Diagnostic test interval......................................................................................................................................... 15
Competence ............................................................................................................................................................. 15
Residual risk ............................................................................................................................................................. 15
Intentional misuse .................................................................................................................................................. 15
Decommissioning................................................................................................................................................... 15
Safety data.................................................................................................................................................................... 16
Safety data values...................................................................................................................................................16
Safety component types....................................................................................................................................... 16
Safety block diagram ............................................................................................................................................. 16
Relevant failure modes ..........................................................................................................................................16
Fault exclusions....................................................................................................................................................... 16
Operation delays..................................................................................................................................................... 16
General rules, notes and definitions.......................................................................................................................16
Validation of the safety functions ......................................................................................................................16
Ambient conditions................................................................................................................................................ 17
Reporting problems and failures related to safety functions...................................................................... 17
Related standards and directives............................................................................................................................18
Compliance with the European Machinery Directive .....................................................................................18
Further information 19

Safety Instructions
Only a qualified electrician who has appropriate knowledge on functional/machine/process safety is
allowed to install, start up and maintain the safety circuit.
WARNING!
This safety function does not disconnect the voltage of the main and auxiliary
circuits from the drive. You must not work on the electrical parts of the drive or the
motor before you have also disconnected the drive system from the electric supply
and ensured by measuring that there is no dangerous voltage present.
WARNING!
After making additions to the drive safety circuit or modifying it, or changing
circuit boards inside the drive, always test the functioning of the safety circuit
according to the acceptance test procedure. Any changes in the electrical
installations of the drive may affect the safety performance or operation of the
drive unexpectedly. All customer-made changes are on the customer’s
responsibility.
WARNING!
Read and obey all safety instructions given for the drive in its hardware manual. If
you ignore them, injury or death, or damage to the equipment can occur.
This manual does not repeat the complete safety instructions of the drive but it only includes the
instructions related to the scope of this manual.

5
Introduction to the manual
3ADW000504R0301 +Q957 Prevention of unexpected start-up en c
Introduction to the manual
Contents of this chapter
This chapter describes the manual in short and gives some general information for the reader. The
chapter also contains a quick reference for implementing a safety system.
Applicability
The manual applies only to DCS880-A cabinet drives and to DCS800-A cabinet drives with plus code
+S880 (exchange of DCS800 with DCS880 drives modules) which have the option: Prevention of
unexpected start-up (POUS) (option: +Q957).
Target audience
The manual is intended for people who install, start up, use and service the safety option of the drive.
Read the manual before working on the drive. You are expected to know the fundamentals of electricity,
wiring, electrical components, electrical schematic symbols, and functional safety.
Contents
The chapters of this manual are briefly described below.
Introduction to the manual (this chapter) introduces this manual.
Option description and instructions describes the safety option and instructs how to wire, start up,
test, validate, use and maintain it. The chapter also contains the safety data.
Related documents
−Product manuals (see the inside of the front cover)
−Circuit diagrams delivered with the drive
−Safety data (if the safety circuit is application engineered)

Abbreviations
Abbreviations used in this manual are listed below.
Abbreviation
Description
Reference
Cat. Category
1. Stop category according to EN/IEC 60204-1
The stop categories are: 0 (uncontrolled stop) and 1
(controlled stop)
2. 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/IEC 60204-1
EN ISO 13849-1
CCF Common cause failure (%) EN ISO 13849-1
DC
Diagnostic coverage
EN ISO 13849-1
DI Digital input
E-stop
Emergency stop
Frame (size)
Relates to the construction type of the drive in question.
For example, several drive types with different power
ratings can have the same basic construction, and a frame
size is used in reference to all those drive types.
HFT
Hardware fault tolerance
IEC 61508,
EN/IEC 62061
PFH
Probability of dangerous failures per hour
IEC 61508,
EN ISO 13849-1,
EN/IEC 62061,
EN/IEC 61800-5-2
PL Performance level (levels are: a, b, c, d and e). Corresponds
to SIL.
EN ISO 13849-1
RO Relay output
SC
Systematic capability
IEC 61508
SIL Safety integrity level IEC 61508,
IEC 61511,
EN/IEC 62061,
EN/IEC 61800-5-2
SILCL
Maximum SIL that can be claimed for a safety function or
subsystem
EN/IEC 62061
SS1
Safe stop 1
EN/IEC 61800-5-2
STO
Safe torque off
EN/IEC 61800-5-2
T1
Proof test interval or lifetime (the smaller one)
IEC 61508,
EN/IEC 62061
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 all relevant standards, directives and local electrical code, and that the
system is tested, verified and validated correctly.

7
Introduction to the manual
3ADW000504R0301 +Q957 Prevention of unexpected start-up en c
Quick reference guide for implementing a safety system
Task

Select the appropriate functional safety standard for the implementation: EN ISO 13849-1,
EN/IEC 62061, IEC 61511 or other

If you select EN/IEC 62061 or IEC 61511, make a safety plan. See EN/IEC 62061.

Assess safety: analyze and evaluate risks (estimate SIL/PL) and define risk reduction
strategies.
Define the safety requirements

Design the safety system. The part of the design made by ABB is described in chapter
Option description and instructions on page 8.

If you made any changes to the delivered safety system, verify the achieved SIL/PL with,
for example, FSDT-01 Functional safety design tool or similar. See
Functional safety design
tool user’s manual (3AXD10000102417 [English]).

Connect the wiring. See section Wiring on page 11.

Set the parameters. See section Parameter settings on page 10.

Validate that the implemented system meets the safety requirements:
−
Do the acceptance test. See section Start-up and acceptance test on page 12.

Write the necessary documentation.

Option description and instructions
Contents this chapter
This chapter describes the +Q957 Prevention of unexpected start-up option and instructs how to wire,
start up, test, validate, use and maintain it. The safety data is also given.
+Q957 basic function description
The Prevention of unexpected start -up (POUS) function disables the drive output stage by utilizing the
STO function.
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 indication lamp is on.
The customer is responsible for installing and connecting the operating switch and the indication lamp
on site. They can be included in the delivery as an option. 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
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
on page 18 .
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.
Basic timing diagram
Stop STO
Ina ctive Active
Speed
POUS
Drive Status
Standstill

9
Option description and instructions
3ADW000504R0301 +Q957 Prevention of unexpected start-up en c
Operation principle +Q957 prevention of unexpected start-up
A41 Drive Control board P7x POUS indication lamp
A65 POUS safety relay S7x POUS reset button
Sxx POUS switch / button Q1/Q2 Mains breaker / DC breaker
T22 24 V power supply KSTOreset Reset indication for safety relay
U1 DCS880 converter CO 24 V from T22 or functional control
from any source

Initial status: The drive is in operation and the motor is at a standstill.
Step
Operation
1. The user activates Prevention of unexpected start-up by switching off the POUS
switch [Sxx].
2. The POUS safety relay [A65] trips and the relay switches off the Safe torque off
(STO) control signals on the drive control board [A41]. The STO cuts off the drive
control pulses preventing motor control and generation of torque.
3.
The aux. contact of safety relay [A65] energizes the indication lamp [P7x].
4. The motor does not generate torque and remains at zero speed while the POUS is
active.
5.
Normal operation resumes after the user:
−releases the POUS button [Sxx] to normal (up) position
−resets the POUS circuit with the POUS reset button [S7x] (if installed; the user
must push the reset button for 0.1 to 3 seconds)
−resets the drive (if the STO indication parameter 31.22 has been set so that a
fault is generated)
−makes sure that the drive has received the start signal (depends on the
configuration, see the firmware manual).
+Q957 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 [A65] trips if it detects a failure (short circuit
between signals, open circuits, redundancy fault) in the safety circuit. The fault reaction function shifts
the drive immediately into the safe state by activating the STO function. The STO function is active until
the fault is repaired. The POUS indication lamp is on until the fault is repaired.
The STO function has its own internal fault diagnostics and fault reaction function.
Parameter settings
This table lists the drive parameters settings for the +Q957 option. For more information, see the
firmware manual.
No.
Name
Value
Description
10.24 RO1 source P.31.98b11 Selects a drive signal to be connected to
relay output RO1. In this case, the RO1 is
energized if the Drive is in STO state and no
STO related fault is active.
31.22 STO indication
run / stop
Fault /
Warning
Selects which indications are given when
one or both Safe torque off (STO) signals
are switched off or lost, depending on
whether the drive is Running / Stopped,
when they occur. When a fault occurs in the
drive, the mains contactor AC-B or DC-B is
opened by the XSMC-MC relay.
Fault/Warning is the recommended setting.
Use Warning / Warning if E-Stop, stop
category 0 (+Q951 or +Q563) is used.

11
Option description and instructions
3ADW000504R0301 +Q957 Prevention of unexpected start-up en c
Hardware settings
Appropriate hardware settings have been preset at the factory for the safety function.
The reset is preset to manual.
Use the switch (1) to change settings
between automatic reset (2) and manual
reset (3).
Power cycle (power off and on) the safety
relay when a setting has been changed.
Wiring
One POUS button and one reset button need to be installed and wired to the drive at the factory. There
must be double contacts in the POUS button and double wiring (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 button.
If needed, install additional POUS buttons on site and wire them to the appropriate terminal block
inside the drive cabinet. See the circuit diagrams delivered with the drive. Follow the rules below:
1. Use only double-contact buttons approved for the POUS circuits.
2. Connect the POUS 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 POUS safety relay trips
and activates the POUS command of the drive as it detects a redundancy fault.
3. Use shielded, twisted pair cable. We recommend a double-shielded cable and gold plated contacts in
the POUS button.
4. Ensure that the sum resistance for one channel (loop resistance) does not exceed 1 kΩ.
5. Follow the general control cable installation instructions given in the drive hardware manual.
You can also install additional reset buttons and indication lamps for the POUS 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.
Follow the rules below:
1. Sum resistance of the external reset circuit may not exceed 1 kΩ.
2. Follow the general control cable installation instructions given in the drive hardware manual.

+Q957 Start-up and acceptance test
You need the Drive composer PC tool or a control panel to perform the start-up and acceptance test.
Initial status: Make sure that the drive is ready for use, that is, you have done the tasks of the drive
start-up procedure. See the hardware manual.
Action
WARNING!
Follow the Safety instructions, page 4. Otherwise, serious injury,
death, or damage to the equipment can occur.
Checks and settings with no voltage connected
If any connections of the POUS circuit have been changed on site (such as wiring of
additional POUS buttons, connection of shipping splits of large drives, etc.), verify
that the connections are correct with the appropriate circuit diagrams.

Check that the hardware settings relevant to the safety function are set as defined
in section Hardware settings on page 11.

M
Settings with voltage connected
Check that the parameters relevant to the safety function are set as defined in
section Parameter settings on page 10.

Ensure that the motor can run and be stopped freely during the test.

Close the mains contactor and switch on the power. The POUS function should be
activated only when the motor is stopped.

Activate the POUS function by turning off the POUS key switch. 
Ensure that the drive indicates POUS as defined in section POUS indications on
page 13.

Ensure that the POUS indication lamp [P7x] switches on.

Ensure that you cannot start the drive and motor from any control location: Switch
the external start signal off and on (in the external control mode) and press the
start key of the panel (in the local control mode).

Deactivate the POUS function by switching on the POUS key switch. Ensure that the
drive does not restart directly after deactivation.

Reset the POUS safety relay by pushing the POUS reset button [S7x] (if installed).

Ensure that the POUS indication lamp [P7x] switches off.

Switch off the drive start signal. If a fault message is generated, reset the drive. See
section Parameter settings on page 13.

Restart the drive and motor and check that they operate normally.

Repeat the test from each operating location (each POUS button and reset button).

Fill in and sign the acceptance test report which verifies that the safety function is
safe and approved for operation.

Error:

13
Option description and instructions
3ADW000504R0301 +Q957 Prevention of unexpected start-up en c
Use of the safety function
Activating
1. Lock the POUS key switch. The switch locks in “ON” (open) position.
Resetting
1. Unlock the POUS switch until it releases.
2. Push the POUS reset button [S7x] (if installed). The indication lamp [P7x] goes out, the POUS
deactivates.
Note: You must push the reset button [S7x] for 0.1 to 3 seconds.
3. Reset the drive if necessary.
4. Make sure that the drive has received the start signal (depends on the configuration, see the
firmware manual).
5. You can now restart the drive.
Note: You have to reset the POUS circuit with the reset button [S7x] also after you have powered up the
drive.
POUS indications
When the POUS is on:
−the drive control program has the warning Safe torque off active,
−the POUS indication lamp [P7x] is illuminated,
−the mode LED of the safety relay [A65] is steady blue.
+Q957 Fault tracing
This table describes the status LEDs of the emergency stop safety relay [A65].
CH1
Mode
CH2
Status
Action
off
off
off
The safety relay is not powered.
Check A1–A2 voltage and
connections.
green
green
green
CH1 and CH2 accepted. Reset made
and outputs activated.
off
flash
green
off
CH1 and CH2 unaccepted. A timer
function is counting down while the
safety relay remains activated.
off
flash
green
green
CH1 unaccepted and CH2 accepted.
A timer function is counting down
while the safety relay remains
activated.
green
flash
green
off
CH1 accepted and CH2 unaccepted.
A timer function is counting down
while the safety relay remains
activated.
off
blue
off
No channels accepted.
Check CH1 and CH2
off
blue
green
CH1 unaccepted, CH2 accepted
Check CH1
green
blue
off
CH1 accepted, CH2 unaccepted
Check CH2
green
blue
green
CH1 and CH2 accepted, the safety
relay waits for reset.
Check reset settings, wiring
and reset/test circuit
green
blue
fast flash
green
Two-channels error: CH2 has been
unaccepted and then accepted
again while CH1 remained accepted.
Check installation. Restore by
opening and closing both
CH:s at the same time.

fast flash
green
blue
green
Two-channels error: CH1 has been
unaccepted and then accepted
again while CH2 remained accepted.
Check installation. Restore by
opening and closing both
CH:s at the same time.
fast flash
green
blue
fast flash
green
Reading error on R1 and R2.
Check installation. Restore by
opening and closing both
CH:s at the same time.
red
fast flash
blue
red
Failsafe mode, a new setting has
been stored.
Power cycle the unit to use
the new setting.
red
flash red
red
Failsafe mode, the system is waiting
for a new setting.
Change the timer setting
switch.
red
fast flash
red
red
The safety relay is in failsafe mode.
Check installation and power
cycle.
red
fast flash
red
fast flash
red
Failsafe mode due to short circuit
between CH2 and 24 VDC or T1
Check and remove the short
circuit.
fast flash
red
fast flash
red
red
Failsafe mode due to short circuit
between CH1 and 24 VDC or T2
Check and remove the short
circuit.
For more information see
2TLC010002M0201 .
+Q957 Maintenance
After the operation of the circuit is tested at start-up, it does need scheduled maintenance testing
during its specified lifetime depending on its usage.
In addition to proof testing, it is a good practice to check the operation of the function when other
maintenance routines of the machinery are carried out.
If you change any wiring or component after the start up, or restore parameters to their default values:
−Use only ABB approved spare parts.
−Register the change to the change log for the safety circuit.
−Test the safety function again after the change.
Follow the rules given in section +Q957 Startup and acceptance test on page 12.
−Document the tests and store the report into the logbook of the machine.
Proof test interval
After the operation of the safety function is validated at start-up, the safety function must be
maintained by periodic proof testing. In high demand mode of operation, the maximum proof test
interval is 20 years. In low demand mode of operation, the maximum proof test interval is one year (high
or low demand as defined in IEC 61508, EN/IEC 62061 and EN ISO 13849-1).

15
Option description and instructions
3ADW000504R0301 +Q957 Prevention of unexpected start-up en c
Diagnostic test interval
Regardless of the mode of operation, it is a good practice to check the operation of the safety function
at least once a year. Do the acceptance test as described in section Start-up and +Q951 acceptance test
on page 12.
The person responsible for the design of the complete safety function should also note the
Requirements from IEC61800-5-2:2016 / EN61800-5-2:2017 for the drives STO circuit:
6.2.2.1.4: Diagnostic test interval when the hardware fault tolerance is greater than zero
The diagnostic test interval of any subsystem of the PDS (SR) shall be appropriate to meet the
required PFH (see 6.2.2.1.1).
NOTE 2: For redundant parts of a PDS (SR) which cannot be tested without disrupting the
application in which the PDS (SR) is used (machine or plant) and where no justifiable technical
solution can be implemented, the following maximum diagnostic test intervals can be considered
as acceptable:
−one test per year for SIL 2, PL d / category;
−one test per three months for SIL 3, PL e / category 3;
−one test per day for SIL 3, PL e / category 4 (not applicable).
PL and category according to ISO 13849-1.
The noted DC Values are taken from SS-EN ISO 13849-1:2016 (E) chapter 4.5.3.
Competence
The maintenance and proof test activities of the safety function must be carried out by a competent
person with adequate expertise and knowledge of the safety function as well as functional safety, as
required by IEC 61508-1 clause 6.
Residual risk
The safety functions are used to reduce the recognized hazardous conditions. In spite of this, it is not
always possible to eliminate all potential hazards. Therefore the warnings for the residual risks must be
given to the operators.
Intentional misuse
The safety circuit is not designed to protect a machine against intentional misuse
Decommissioning
When you decommission a POUS circuit or a drive, make sure that the safety of the machine is
maintained until the decommissioning is complete.

Safety data
The safety data given below is valid for the default design of the safety circuit. In case the final design
differs from the default, it is obligation of the changing person to calculate new safety data and deliver
it separately to the customer.
Safety data values
Drive module
frame size
SIL1) /
SILCL
SC
PL1)
PFH2) [1/h]
DC [%]
Cat.
HFT
CCF
Lifetime
[a]
T13)4) [a]
H1 … H8
3
3
e
5.4 E-8
>90
3
1
80
20
20/1
1) The drive may be used for applications with the given SIL / PL only if the function is tested regularly
(see chapter: test interval above).
2) PFH values are according to EN ISO 13849.
3) See the recommendation of use CNB/M/11.050 published by the European coordination of notified
bodies for lower T1 requirement and also IEC61800-5-2:2016 / EN61800-5-2:2017 6.2.2.1.4 Note 2 for
guidance.
4) T1 = 20a is used with high demand mode of operation. See also section Proof test interval on page 14.
Safety component types
Safety component types as defined in IEC 61508-2:
−POUS button: type A
−safety relays: type A
−drive STO circuit:
−frame sizes H1 ... H8: type A
Safety block diagram
The components that are included in the safety circuit are shown in the safety block diagram below.
POUS
Button
POUS
Safety
Relay
Drive
module
(STO)
Relevant failure modes
Internal failures of safety relays, the POUS button and STO. These failures are included in the PFH value
of the function.
Fault exclusions
Fault exclusions (not considered in the calculations):
−any short and open circuits in the cables of the safety circuit
−any short and open circuits in the cabinet terminal blocks of the safety circuits.
Operation delays
POUS total delay: max. 650 ms.
General rules, notes and definitions
Validation of the safety functions
You must do an acceptance test (validation) to validate the correct operation of safety functions.

17
Option description and instructions
3ADW000504R0301 +Q957 Prevention of unexpected start-up en c
Validation procedure
You must do the acceptance test using the checklist given in section Start-up and acceptance test on
page 12:
−at initial start-up of the safety function
−after any changes related to the safety function (wiring, components, safety function related
parameter settings etc.)
−after any maintenance action related to the safety function.
The acceptance test must include at least the following steps:
−you must have an acceptance test plan
−you must test all commissioned functions for proper operation, from each operation location
−you must document all acceptance tests.
Acceptance test reports
You must store the signed acceptance test reports in the logbook of the machine. The report must
include, as required by the referred standards:
−a description of the safety application (including a figure)
−a description and revisions of safety components that are used in the safety application
−a list of all safety functions that are used in the safety application
−a list of all safety related parameters and their values
−documentation of start-up activities, references to failure reports and resolution of failures
−the test results for each safety function, checksums, date of the tests and confirmation by the test
personnel.
You must store any new acceptance test reports performed due to changes or maintenance in the
logbook of the machine.
Competence
The acceptance test of the safety function must be carried out by a competent person with adequate
expertise and knowledge of the safety function as well as functional safety, as required by IEC 61508-1
clause 6.
The test procedures and report must be documented and signed by this person.
Ambient conditions
For the environmental limits for the safety functions and the drive, refer to the hardware manual.
Reporting problems and failures related to safety functions
Contact your local ABB representative.

Related standards and directives
Standard
Name
EN 60204-1:2006 + AC:2010
IEC 60204-1:2005 + A1:2008
Safety of machinery – Electrical equipment of machines –
Part 1: General requirements
IEC 61508-1:2010 Functional safety of electrical/electronic/programmable
electronic safety related systems - Part 1: General
requirements.
IEC 61508-2:2010
Functional safety of electrical/electronic/programmable
electronic safety related systems - Part 2: Requirements for
electrical/electronic/ programmable electronic safety
related systems.
EN 61800-5-2:2017
IEC 61800-5-2:2016
Adjustable speed electrical power drive systems –
Part 5-2: Safety requirements – Functional
EN 62061:2005 + AC:2010 +
A1:2013 + A2:2015
IEC 62061:2015
Safety of machinery – Functional safety of safety-related
electrical, electronic and programmable electronic control
systems
EN ISO 12100:2010
Safety of machinery – General principles for design – Risk
assessment and risk reduction
ISO 13849-1:2015
Safety of machinery – Safety-related parts of control
systems – Part 1: General principles for design
EN ISO 13849-2:2012
Safety of machinery – Safety-related parts of control
systems – Part 2: Validation
EN ISO 13850:2015
ISO 13850:2015
Safety of machinery. Emergency stop. Principles for design
IEC 61511-1:2016 Functional safety – Safety instrumented systems for the
process industry sector
IEC 61326-3-1: 2008 Electrical equipment for measurement, control and
laboratory use – EMC requirements – Part 3-1: Immunity
requirements for safety-related systems and for equipment
intended to perform safety-related functions (functional
safety) – General industrial applications
2006/42/EC
European Machinery Directive
Other
Machine-specific C-type standards
Compliance with the European Machinery Directive
The drive is an electronic product which is covered by the European Low Voltage Directive. However, the
drive internal safety function of this manual (option +Q957) is in the scope of the Machinery Directive as
a safety component. This function complies with European harmonized standards such as EN/IEC
61800-5-2. The declaration of conformity is delivered with the drive.

19
Further information
3ADW000504R0301 +Q957 Prevention of unexpected start-up en c
Further information
Product and service inquiries
Address any inquiries about the product to your local ABB representative, quoting the type designation
and serial number of the unit in question. A listing of ABB sales, support and service contacts can be
found by navigating to
www.abb.com/searchchannels .
Product training
For information on ABB product training, navigate to new.abb.com/service/training .
Providing feedback on ABB manuals
Your comments on our manuals are welcome. Navigate to new.abb.com/drives/manuals-feedback-form .
Document library on the Internet
You can find manuals and other product documents in PDF format on the Internet at
www.abb.com/drives/documents

DCS Family

ABB Automation Products
Wallstadter-Straße 59
68526 Ladenburg • Germany
Tel: [phone]
Fax: [phone]
www.abb.com/dc-drives *504R0301A0090000*
*504R0301A0090000*
Ident. No.: 3ADW000504
R0301 Rev C
02.2020