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ABB ACS880 User Manual
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ABB ACS880 User Manual

Safely-limited speed without the encoder interface (option +q966) for multidrives
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OPTIONS FOR ABB DRIVES
Safely-limited speed without the encoder
interface (option +Q966) for ACS880
multidrives
User's manual

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Summary of Contents for ABB ACS880

  • Page 1 — OPTIONS FOR ABB DRIVES Safely-limited speed without the encoder interface (option +Q966) for ACS880 multidrives User's manual...
  • Page 3 Safely-limited speed without the encoder interface (option +Q966) for ACS880 multidrives User's manual Table of contents 1. Safety instructions 4. Electrical installation 7. Start-up and validation test 3AUA0000145935 Rev H Original instructions EFFECTIVE: 2022-04-22...

  • Page 5: Table Of Contents

    Table of contents 5 Table of contents 1 Safety instructions Contents of this chapter ................Use of warnings and notes ............... Instructions for functional safety circuits ............Electrical safety precautions ..............2 Introduction to the manual Contents of this chapter ................Applicability ..................
  • Page 6 6 Table of contents FSO module parameter settings ..............General parameters ................Parameters for the STO function ............. Parameters for the SSE function ............. Parameters for the SLS function ............. Parameters for the SMS function ............Parameters for the SSM function ............Inverter unit parameter settings ..............

  • Page 7: Safety Instructions

    Safety instructions 7 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.

  • Page 8: Instructions For Functional Safety Circuits

    8 Safety instructions 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.

  • Page 9: Electrical Safety Precautions

    Safety instructions 9 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.
  • Page 10 10 Safety instructions Important! Repeat the measurement also with the DC voltage setting of the tester. Measure between each phase and ground. There is a risk of dangerous DC voltage charging due to leakage capacitances of the motor circuit. This voltage can remain charged for a long time after the drive power-off.

  • Page 11: Introduction To The Manual

    This chapter also contains a quick reference guide for implementing a safety system. Applicability This manual is applicable to ACS880 air-cooled and liquid-cooled multidrives which have the option +Q966: Safely-limited speed (SLS) without encoder, with FSO-12 (option +Q973) or FSO-21 (option +Q972).

  • Page 12: Target Audience

    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.

  • Page 13: Terms And Abbreviations

    3AUA0000094606 Functional safety design tool user’s manual 3AXD10000102417 Safety ACS880 multidrive cabinets and modules safety instructions 3AUA0000102301 ACS880 liquid-cooled multidrive cabinets and modules safety instructions 3AXD50000048633 Functional safety; Technical guide No. 10 3AUA0000048753 ABB Safety information and solutions www.abb.com/safety Options ACX-AP-x assistant control panels user’s manual...
  • Page 14 14 Introduction to the manual Term Description Safe acceleration range Safe brake control Safety integrity level (1…3) (IEC 61508, IEC 62061, IEC 61800-5-2) Safely-limited speed SLS monitoring limit The speed limit at which SLS monitoring is started, located in the middle of SLS trip limit and SLS limit.

  • Page 15: Option Description

    Overview Option +Q966 uses the FSO-12 safety functions module (option +Q973) or FSO-21 safety functions module (option +Q972). ABB installs the FSO modules to the inverter units and sets the delivery configuration for the option at the factory. With option +Q966, these safety functions are configured in the FSO modules at the factory: •...

  • Page 16: Summary Of Wirings And Settings

    The user connects the SSM indication signal (for example, an indication lamp) to the FSO module. • ABB sets the safety IO settings for the SSM output at the factory to agree with the circuit diagrams. • The SSM positive and negative speed limits are FSO module parameters that the user...

  • Page 17: Operation Principle

    Option description 17 Operation principle SLS function ￭ The Safely-limited speed (SLS) function limits the motor speed so that it does not exceed the user-defined speed limits when the function is active. The user defines the SLS limits and trip limits. When the user activates the SLS function, the FSO modules send a SLS request to the inverter units .

  • Page 18: Sls With Speed Above The Monitored Speed - Time Monitoring

    18 Option description The user or a PLC de-energizes the applicable digital inputs of the FSO module. This activates the SLS request. After the safety function response time (A), the FSO module starts to monitor the motor speed. The FSO module energizes the digital output that indicates the SLS status. While the monitoring is active, the inverter unit limits the motor speed so that it stays at or below the SLS1 limit positive.
  • Page 19 Option description 19 The user or a PLC de-energizes the applicable digital inputs of the FSO module. This activates the SLS request. The FSO module starts a counter for time (B). After the safety function response time (A), the inverter unit starts to decelerate the motor according to the user-defined deceleration ramp.

  • Page 20: Sls With Speed Above The Monitored Speed - Ramp Monitoring

    20 Option description SLS with speed above the monitored speed - ramp monitoring This time scheme diagram illustrates the operation of the SLS function with ramp monitoring. The motor speed is above the monitored speed when the SLS function is activated. Motor speed STO.14 Time...

  • Page 21: Sls Reaction When Modulation Is Lost During Deceleration Ramp

    Option description 21 The user or a PLC energizes the applicable digital inputs of the FSO module. This deactivates the SLS request. The FSO module acknowledges the SLS function automatically. This is set to be automatic by an FSO parameter (SLSx.02), and no external acknowledgement input is used.
  • Page 22 22 Option description Example 1: Modoff delay time – modulation returns before modoff delay In this example, parameter SLSx.05 is set to Modoff delay time. The time diagram below describes the operation of the SLS function when modulation is lost during the deceleration ramp, and the modulation returns before the modoff delay time has run out.
  • Page 23 Option description 23 Example 2: SAR1 ramp monitoring active In this example, parameter SLSx.05 is set to Monitoring active. The time diagram below describes the operation of the SLS function when modulation is lost during the deceleration ramp. Motor speed Time SLS request SAR1 monitoring...
  • Page 24 24 Option description Example 3: SAR1 ramp monitoring and SLS modoff delay time active In this example, parameter SLSx.05 is set to Monitoring active and modoff delay time. The time diagram below describes the operation of the SLS function when modulation is lost during the deceleration ramp.
  • Page 25 Option description 25 Example 4: Time monitoring active In this example, parameter SLSx.05 is set to Monitoring active. The time diagram below describes the operation of the SLS function when modulation is lost during the deceleration ramp. Motor speed Time SLS request SLSx.04 time delay monitoring...

  • Page 26: Sms Function

    26 Option description Example 5: Monitoring and modoff delay time disabled In this example, parameter SLSx.05 is set to Monitoring and modoff delay time disabled. The time diagram below describes the operation of the SLS function when modulation is lost during the deceleration ramp. Motor speed Time SLS request...

  • Page 27: Ssm Function

    The SSM1 function is used as an example and in the delivered default settings of the +Q966 option. ABB activates the SSM1 function at the factory. The user sets the SSM positive and negative speed limits at the start-up. For more information, refer to chapter...

  • Page 28: Operation Principle Diagram

    28 Option description This time scheme diagram illustrates the operation of the SSM1 function. Motor speed Time SSM indication SSM1 limit positive (parameter SSMx.13) SSM1 limit negative (parameter SSMx.12) The motor speed goes above the SSM limit positive. The SSM indication goes off. The motor speed goes below the SSM limit positive.
  • Page 29 Option description 29 -A41 -A41 -T11.x -T11.x -A41 -A41 -T11.x -T11.x XSTO XSTO XSTO XSTO SGND SGND XSTO XSTO SGND SGND XSTO XSTO -A68 -A68 -A68 -A68 X11 1 X11 1 X11 1 X11 1 X11 4 X11 4 X11 3 X11 3 X11 4 X11 4...

  • Page 30: Fault Reaction Function

    30 Option description 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. Examples of different failures: • a short or open circuit or redundancy failure of the SLS activation switch wiring chain •...

  • Page 31: Electrical Installation

    13, 14, 15, 16 FSO X114 22, 23 27, 28, 29, 30 ABB installs the FSO modules and the wiring between the FSO modules and the inverter units at the factory. SLS function ￭ You must connect the SLS request signal to the FSO module on site. You can also connect...

  • Page 32: Sms Function

    In this case, the safety data that ABB has calculated for the function is not valid. Use a shielded, twisted pair cable. ABB recommends double-shielded cable.

  • Page 33: Parameter Settings

    IEC 61508-1 clause 6. In this context, the person must have expertise and knowledge of functional safety, the safety functions and the configuration of the FSO module. ABB has training courses on the FSO module. FSO module parameter settings The default parameter values shown below are example values for the safety functions described in this manual.

  • Page 34: General Parameters

    34 Parameter settings Note: The FSO module has a factory reset button. The factory reset button clears the configuration and sets the parameters to the factory default values. These values are not the same as the pre-set values in an FSO module that was ordered as an option (with a plus code).

  • Page 35: Parameters For The Sto Function

    Parameter settings 35 Index Name Example value Description FSOGEN.51 Zero speed without 90 rpm Sets the general zero speed limit for safety encoder functions when a safety encoder is not used. This parameter is relevant when the SSE function is activated and if parameter SSE.13 SSE function is set to Emergency ramp.

  • Page 36: Parameters For The Sse Function

    36 Parameter settings Index Name Example value Description STO.14 Time to zero speed 2000 ms The time it takes for the motor to coast to a with STO and modoff standstill from maximum process speed. This must be measured with the Drive Composer pro PC tool when an encoder is used for motor control (otherwise you have to make sure that the motor shaft has...
  • Page 37 For more information, refer to the FSO module user's manual. Zero speed is defined by parameter FSOGEN.51 Zero speed without encoder. For option +Q966, ABB sets this parameter to value Immediate STO at the factory. Ad- just the default value when necessary. SSE.14...
  • Page 38 38 Parameter settings Index Name Example value Description SSE.16 SSE ramp zero 0 ms Sets an extra delay time for the inverter unit speed delay for STO STO activation at the zero speed in the SSE function. The FSO module uses a speed estimation, which can differ from the actual shaft speed of the motor.

  • Page 39: Parameters For The Sls Function

    There are four separate SLS functions (SLS1…4) in the FSO module. The SLS functions are identical and the configuration is done similarly, only the parameter numbers differ. The SLS1 function is shown as an example. ABB has activated the SLS1 function at the factory. For more information, see FSO module user’s manual.
  • Page 40 Ramp monitoring: SAR1 parameters define the deceleration ramp and monitoring limits. See parameters 200.112, SARx.21, SARx.22 and SARx.02. For option +Q966, ABB sets this parameter to value Ramp at the factory. Adjust the de- fault value when necessary. SLSx.04 SLS time delay...
  • Page 41 DI X113:2 & X114:2 Sets the digital input that is connected to the primary input of the SLS function with limits 1. For option +Q966, ABB has configured the SLS request signal to these digital inputs at the factory. SLSx.13...
  • Page 42 Active high: The digital output is on when the indicated signal is active. For option +Q966, ABB has configured the SLS indication signal to this digital output at the factory. Make sure that this value corres- ponds to the actual wiring. Refer to the cir-...

  • Page 43: Parameters For The Sms Function

    The SSM1 function is shown as an example. ABB has activated the SSM1 function at the factory. For more information, refer to the FSO-21 module user’s manual.

  • Page 44: Inverter Unit Parameter Settings

    Refer to the circuit dia- grams of the delivery. Inverter unit parameter settings The table that follows gives the parameters related to the safety function in the ACS880 primary control program. The parameters are set at the factory. Name...
  • Page 45 Parameter settings 45 speed along its acceleration ramp. Inverter unit parameters define the acceleration ramp and it is not monitored. For the parameter settings in the inverter unit, refer to the firmware manual.

  • Page 47: Use Of The Safety Function

    Use of the safety function 47 Use of the safety function Contents of this chapter This chapter describes the use of the safety function with factory default settings. Activating and deactivating the SLS function To activate the SLS function, de-energize the SLS inputs of the FSO module. When the SLS monitoring is on and the motor speed is below the SLS limit: •...

  • Page 48: Activating And Deactivating The Ssm Function

    48 Use of the safety function When the inverter unit trips after an SMS trip limit hit: • the FSO module generates an indication, defined by parameter FSOGEN.62 • the inverter unit generates an indication, defined by parameter 31.22. If a trip limit hit occurs and the FSO module or inverter unit is configured to trip on a fault, you must reset the faults from the inverter unit.

  • Page 49: Start-Up And Validation Test

    Start-up and validation test 49 Start-up and validation test Contents of this chapter This chapter describes the start-up, validation test procedure, and validation of the safety function. Validation of the safety functions You must do a validation test to make sure that the safety function operates correctly and according to the safety requirements.

  • Page 50: Validation Test Reports

    Note: The SLS validation test procedure described in this chapter does not test the trip limits, because the SLS function limits the motor reference speed to the SLS limit. ABB has validated the functionality of trip limits in the verification tests.
  • Page 51 Start-up and validation test 51 Action WARNING! Obey the safety instructions. If you ignore them, injury or death, or damage to the equipment can occur. Initial status Make sure that the drive is ready for use, that is, you have done the tasks of the drive start-up procedure. Refer to the hardware manuals.
  • Page 52 52 Start-up and validation test Action Validation test ABB recommends that you monitor at least these signals with the Drive Composer PC tool: • 01.01 Motor speed used (rpm) • 01.02 Motor speed estimated (rpm) • 01.07 Motor current (A) •...
  • Page 53 Start-up and validation test 53 Action For the SLS function: When the SLS request signal is on, make sure that you cannot increase the reference speed above the SLS limit: • with the panel in the local control mode • with an external speed reference signal in the external control mode. The LOC and REM buttons of the control panel or the Drive composer PC tool switch between the local and external controls.

  • Page 55: Maintenance

    If you change the wiring or a component after the start-up, replace a power unit or its circuit boards, replace the FSO module, modify FSO module parameters, or restore parameters to their factory default values: • Use only ABB-approved spare parts. • Register the change to the change log for the safety circuit. •...

  • Page 56: Functional Safety Components

    The remaining mission time of the whole circuit is however determined by its oldest component. Contact your local ABB service representative for more information. Competence The person who does the maintenance and proof test activities of the safety function must be a competent person with expertise and knowledge of the safety function and functional safety, as required by IEC 61508-1 clause 6.

  • Page 57: Decommissioning

    Maintenance 57 Decommissioning When you decommission a safety function network or a part of it, or an inverter unit, make sure that the functional safety of the machine is maintained by other means until the decommissioning is completed.

  • Page 59: Technical Data

    R7i…R8i inverter modules: type B. Safety block diagrams ￭ Each multidrives delivery is unique. If included in the customer order, ABB defines the safety block diagram for the safety function and delivers the diagram separately to the customer. Relevant failure modes ￭...

  • Page 60: Fault Exclusions

    60 Technical data These failures are included in the failure rate value of the function. Fault exclusions ￭ Fault exclusions (not considered in the calculations): • short and open circuits in the cables of the safety circuit • short and open circuits in the cabinet terminal blocks of the safety circuits. Operation delays ￭...

  • Page 61: Compliance With The European Machinery Directive

    Technical data 61 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 is in the scope of the Machinery Directive as a safety component.

  • Page 63: 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.
  • Page 64 3AUA0000145935H © Copyright 2022 ABB. All rights reserved. Specifications subject to change without notice.

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