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ABB ACS880 Series Manual

Safely-limited speed with the encoder interface (option +q965)
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OPTIONS FOR ABB DRIVES
Safely-limited speed with the encoder
interface (option +Q965) for
ACS880-07/07LC/17/17LC/37/37LC drives
User's manual

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Summary of Contents for ABB ACS880 Series

  • Page 1 — OPTIONS FOR ABB DRIVES Safely-limited speed with the encoder interface (option +Q965) for ACS880-07/07LC/17/17LC/37/37LC drives User's manual...
  • Page 3 Safely-limited speed with the encoder interface (option +Q965) 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 3AXD50000019727 Rev F EFFECTIVE: 2020-09-30...

  • 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 Competence ..................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 ............FSE-31 module and safety pulse encoder related parameters ......

  • 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 11: Introduction To The Manual

    Introduction to the manual 11 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 +Q965: Safely-limited speed (SLS) with encoder, with FSO-21 and FSE-31.

  • Page 12: Exclusion Of Liability

    12 Introduction to the manual 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 Delivered with the drive Part lists Delivered with the drive Safety data report (if the safety circuit is different from the default design) www.abb.com/drives/documents for all manuals on the Internet. ACS880-07 (45 to 710 kW) manuals ACS880-07 (560 to 2800 kW)

  • Page 14: Terms And Abbreviations

    14 Introduction to the manual Terms and abbreviations Term Description Cat. 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.

  • Page 15: Option Description

    Option +Q965 uses the FSO-21 safety functions module (option +Q972) and the FSE-31 pulse encoder interface module (option +L521). ABB installs the FSO-21 and FSE-31 modules to the drive and sets the delivery configuration for the option at the factory.

  • Page 16: Summary Of Wirings And Settings

    • The digital input of the FSO module to which the SLS activation signal is connected, is selected as the input for the SLS request. ABB sets the safety IO settings for SLS input and output at the factory to agree with the circuit diagrams.

  • Page 17: Operation Principle

    • The user wires 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 must set at the start-up.

  • Page 18: Sls With Speed Below The Monitored Speed

    18 Option description SLS with speed below the monitored speed This time scheme diagram illustrates the operation of the SLS function. The motor speed is below the monitored speed when the user activates the SLS function. Motor speed Time SLS request SLS status &...
  • Page 19 Option description 19 1. The user or a PLC de-energizes the applicable digital inputs of the FSO module. This activates the SLS request. 2. 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 drive limits the motor speed so that it stays at or below the SLS1 limit positive.

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

    20 Option description SLS with speed above the monitored speed - time monitoring This time scheme diagram illustrates the operation of the SLS function with time monitoring. The motor speed is above the monitored speed when the SLS function is activated. Motor speed SLSx.04 Time...
  • Page 21 Option description 21 3. The actual motor speed reaches the SLS1 limit positive. The drive limits the motor speed reference so that the motor speed stays at or below the SLS1 limit positive. The FSO module monitors the actual motor speed. If the motor speed goes above the SLS1 trip limit positive (D), the FSO module activates the SSE function (see section SLS with speed below the monitored speed (page...

  • Page 22: Sls With Speed Above The Monitored Speed - Ramp Monitoring

    22 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 Time SLS request...

  • Page 23: Sls Reaction When Modulation Is Lost During Deceleration Ramp

    Option description 23 3. The actual motor speed reaches the SLS1 limit positive. The drive limits the motor speed reference so that the motor speed stays below the SLS1 limit positive. The FSO module monitors the actual motor speed. If the motor speed goes above the SLS1 trip limit positive (C), the FSO module activates the SSE function (see section SLS with speed below the monitored speed (page...
  • Page 24 24 Option description Value of parameter SLSx.05 When modulation is lost When modulation comes back SLS ramp modoff reaction Modoff delay time Ramp monitoring (SAR1) is disabled, Ramp monitoring (SAR1) is restarted, Time monitoring is suspended. Time monitoring is continued. Monitoring active Last valid speed frozen and used.
  • Page 25 Option description 25 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 26 26 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 27 Option description 27 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 28: Sms Function

    28 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 29: Ssm Function

    The SSM1 function is used as an example and in the delivered default settings of the +Q965 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, see chapter Parameter settings and the FSO module user's manual.

  • Page 30: Drive Modulation Loss When Encoder Feedback Is Used

    30 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) 1. The motor speed goes above the SSM limit positive. The SSM indication goes off. 2.

  • Page 31: Operation Principle Diagram

    Option description 31 Operation principle diagram ￭ This diagram shows the connections of the FSO module. The figure shows a simplified operation principle. For a more detailed description, refer to the circuit diagrams delivered with the drive. -A41 -A46 8 SLO T2 -T11.x XSTO...

  • Page 32: Fault Reaction Function

    32 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 33: Drive Sto Function

    Option description 33 Drive STO function ￭ The drive STO function has internal fault diagnostics and a fault reaction function, which causes a fault trip if it detects a redundancy fault of STO control signals or an internal failure. See the hardware and firmware manuals of the drive.

  • Page 35: Electrical Installation

    There is a separate user interface terminal block [X965] inside the drive cabinet. The user interface terminal block [X965] is connected to the extension terminal block [X68]. ABB installs the FSO and FSE-31 modules and the wiring between the FSO module and the user interface at the factory.

  • Page 36: Sls Function

    In this case, the safety data that ABB has calculated for the function is not valid. 2. Use a shielded, twisted pair cable. ABB recommends double-shielded cable.

  • Page 37: 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 38: General Parameters

    38 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 39: Parameters For The Sto Function

    Parameter settings 39 Index Name Example value Description FSOGEN.52 Zero speed with en- 10 rpm Sets the general zero speed limit for safety coder functions when a safety encoder is in use. This parameter is relevant when the SSE function is activated and if parameter SSE.13 SSE function is set to Emergency ramp.

  • Page 40: Parameters For The Sse Function

    40 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 Drive composer pro PC tool when an encoder is used for motor control (otherwise you have to make sure that the motor shaft has stopped rotat-...
  • Page 41 Zero speed is defined by parameter FSOGEN.51 Zero speed without encoder or FSOGEN.52 Zero speed with encoder. For option +Q965, ABB sets this parameter to value Immediate STO at the factory. Ad- just the default value when necessary. SSE.14...
  • Page 42 42 Parameter settings Index Name Example value Description SSE.16 SSE ramp zero 0 ms Sets an extra delay time for the drive STO speed delay for STO activation at the zero speed in the SSE function. With this parameter, the FSO module delays the STO activation so that the drive is able to reach the shaft zero speed before the FSO module activates the STO function.

  • Page 43: 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 44 Ramp monitoring: SAR1 parameters define the deceleration ramp and monitoring limits. See parameters 200.112, SARx.21, SARx.22 and SARx.02. For option +Q965, ABB sets this parameter to value Ramp at the factory. Adjust the de- fault value when necessary. SLSx.04 SLS time delay...
  • Page 45 Sets the digital output that is connected to the primary output of the SLS1 function. Active when the SLS monitoring is on. For option +Q965, ABB has configured the SLS indication signal to this digital output at the factory. SAR1 ramp settings 200.112...

  • Page 46: Parameters For The Sms Function

    Active high: The digital output is on when the indicated signal is active. For option +Q965, 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. See the circuit diagrams of the delivery.

  • Page 47: Fse-31 Module And Safety Pulse Encoder Related Parameters

    Parameter settings 47 SSM1 function is shown as an example. ABB has activated the SSM1 function at the factory. For more information, see FSO-21 module user’s manual. Index Name Example value Description SSMx.01 SSM1 activity and Version 1 Activates or deactivates the SSM1 function version and shows the version of the SSM1 function.
  • Page 48 48 Parameter settings Index Name Example value Description S_ENCGEN.01 Safe pulse encoder Version 1 Activates the safety encoder and shows the version version parameter group S_ENCGEN. S_ENCGEN.11 FSE diagnostic fail- Sets the action taken when there is a prob- ure reaction lem with the FSE-31 module or the safety encoder.

  • Page 49: Drive Parameter Settings

    FSO module activates the drive STO function. 1) Value set by ABB at the factory for the default design. The table that follows shows the parameters that you must set when you use a safety encoder.
  • Page 50 50 Parameter settings In SLS with time monitoring, the drive (parameter 23.13 Deceleration time 1 or 23.15 Deceleration time 2) always defines the deceleration ramp. In SLS with ramp monitoring, the drive uses either the ramp settings in the FSO module or the drive.

  • Page 51: Use Of The Safety Function

    Use of the safety function 51 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 (0 V) the applicable digital inputs of the FSO module.

  • Page 52: Activating And Deactivating The Ssm Function

    52 Use of the safety function When the drive trips after an SMS trip limit hit: • the FSO module generates a fault (see parameter FSOGEN.62) • the drive generates an event according to parameter 31.22. The indications that the FSO module generates are configurable. For more information, see chapter Parameter settings in this manual and chapter Fault tracing in the FSO module...

  • Page 53: Start-Up And Validation Test

    Start-up and validation test 53 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 validate the correct operation of safety functions. Competence ￭...

  • Page 54: 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 55 Start-up and validation test 55 Action Make sure that the FSO STO function is configured and validated. Internal monitoring of the FSO module can trigger the STO function even if you have not defined an external request signal. The STO function must be validated before other safety functions. Note: If parameter S_ENCGEN.11 is set to Est switch not active load, both STO function with speed estimate and STO function with encoder feedback must be tested - most importantly, the value of parameter STO.14 must be set according to the application requirements.
  • Page 56 56 Start-up and validation test Action Validation test ABB recommends that you monitor 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) • 01.10 Motor torque (%) •...
  • Page 57 Start-up and validation test 57 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 59: Maintenance

    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. • If parameters were restored to the factory default values: Set the parameters related to the safety function.

  • Page 60: Competence

    60 Maintenance The person responsible for the design of the complete safety system should also note the Recommendation of Use CNB/M/11.050 published by the European co-ordination of Notified Bodies for Machinery concerning dual-channel safety-related systems with electromechanical outputs: • When the safety integrity requirement for the safety function is SIL 3 or PL e (cat. 3 or 4), the proof test for the function must be done at least every month.

  • Page 61: Technical Data

    Technical data 61 Technical data Contents of this chapter This chapter lists the safety data, describes the ambient conditions and gives a list of standards related to the product. Safety data Safety performance with different safety pulse encoders ￭ See FSE-31 pulse encoder interface module user’s manual (3AXD50000016597 [English]). This table gives the maximum PFH values for the safety encoder to fulfill the requirements for each safety integrity level.

  • Page 62: Safety Data Values

    ￭ This safety data is valid for the default design of the safety circuit described in this manual. If the final design is different from the default, ABB calculates new safety data and delivers it separately to the customer. The safety data calculations are based on the assumption that the emergency stop is used once a month.

  • Page 63: Relevant Failure Modes

    Technical data 63 SLS switch (user-defined) FSO module, and FSE module Drive STO Relevant failure modes ￭ Relevant failure modes are: • internal failures of the FSO module, the FSE module, and the drive STO. These failures are included in the failure rate value of the function. Fault exclusions ￭...

  • Page 64: Compliance With The European Machinery Directive

    64 Technical data Standard Name 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 IEC 61511-1:2016 Functional safety – Safety instrumented systems for the process industry sector – Part 1: Framework, definitions, system, hardware and application programming requirements EN 61800-5-2:2007 Adjustable speed electrical power drive systems –...

  • Page 65: 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 66 3AXD50000019727F © Copyright 2020 ABB. All rights reserved. Specifications subject to change without notice.

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