ABB ACS880-07 User manual

Brand: ABB

Model: ACS880-07

Type: User manual

This manual is also suitable for

—

OPTIONS FOR ABB DRIVES

Emergency stop, stop category 1 (option

+Q952) for ACS880-07/17/17LC/37/37LC

drives

User's manual

Emergency stop, stop category 1

(option +Q952) for

ACS880-07/17/17LC/37/37LC drives

User's manual

Table of contents

1. Safety instructions

4. Electrical installation

6. Start-up and acceptance test

EFFECTIVE: 2019-06-28

Table of contents

1 Safety instructions

7Contents of this chapter ..........................................................................

7Use of warnings and notes ......................................................................

7Instructions for functional safety circuits .......................................................

8Electrical safety precautions ....................................................................

2 Introduction to the manual

9Contents of this chapter ..........................................................................

9Applicability ........................................................................................

9Target audience ...................................................................................

9Exclusion of liability ...............................................................................

10Quick reference guide for taking a safety function into use ................................

10Related manuals ..................................................................................

12Terms and abbreviations .........................................................................

3 Option description

13Contents of this chapter ..........................................................................

13Overview ...........................................................................................

13Operation principle ................................................................................

14ACS880-07 drives, frames R6 to R11 and ACS880-17/-37 drives, frame R8 ........

16ACS880-17/37 drives, frame R11 ...........................................................

18ACS880-07 drives, frames nxDXT + nxR8i ................................................

20ACS880-17/37 and -17LC/37LC drives, frames nxR8i + nxR8i ........................

21Fault reaction function ............................................................................

22Parameter settings ................................................................................

22Drive parameter settings .....................................................................

Additional parameter settings for ACS880-07 drives, frames nxDXT + nxR8i and

ACS880-17/17LC/37/37LC drives, frames nxR8i + nxR8i ..............................

23Additional parameter settings for ACS880-17/37, frames R8 and R11 ................

23Hardware settings ................................................................................

4 Electrical installation

25Contents of this chapter ..........................................................................

25Wiring ...............................................................................................

26Customer-installed main breaker in ACS880-17LC/37LC drives .......................

5 Use of the safety function

27Contents of this chapter ..........................................................................

27Activating the safety function ....................................................................

27Resetting the safety function ....................................................................

6 Start-up and acceptance test

29Contents of this chapter ..........................................................................

Table of contents 5

29Validation of the safety functions ...............................................................

29Competence ...................................................................................

29Validation procedure ..........................................................................

30Acceptance test reports ......................................................................

30Start-up and acceptance test ...................................................................

7 Fault tracing

33Contents of this chapter ..........................................................................

33Fault tracing .......................................................................................

34ACS880-07 drives, frames R6 to R11 and ACS880-17/37 drives, frame R11 ........

34Reporting problems and failures related to safety functions ................................

8 Maintenance

35Contents of this chapter ..........................................................................

35Safety circuit maintenance ......................................................................

35Proof test interval .................................................................................

36Competence .......................................................................................

36Residual risk .......................................................................................

36Intentional misuse ................................................................................

36Decommissioning .................................................................................

9 Technical data

37Contents of this chapter ..........................................................................

37Safety data .........................................................................................

37Safety data values ............................................................................

38ACS880-07 drives with a main contactor (option +F250) ............................

40ACS880-17/37 drives with a main contactor (option +F250) ........................

42ACS880-07/17/17LC/37/37LC drives with a main breaker (option +F255) .......

43ACS880-17LC/37LC drives without a main breaker ..................................

43Safety component types ......................................................................

43Safety block diagrams ........................................................................

Diagram 1: ACS880-07 drives, frames R6 - R11 and ACS880-17/-37 drives, frame

R8, with one contactor (A145 – AF1250) or circuit breaker .........................

44Diagram 2: ACS880-17/37 drives, frame R11 .........................................

Diagram 3: ACS880-07 drives, frames n x R8i, 12-pulse variants with two

contactors (2 x AF2050) ..................................................................

44Diagram 4: ACS880-17/37 drives, frames nxR8i + nxR8i ...........................

Diagram 5: ACS880-07 drives, frames n x R8i with one contactor (AF1250 –

AF2050) .....................................................................................

44Relevant failure modes .......................................................................

44Fault exclusions ...............................................................................

44Operation delays ..............................................................................

45Ambient conditions ...............................................................................

45ACS880-07 drives, frames R6 to R11 ......................................................

45Related standards and directives ...............................................................

46Compliance 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.

Instructions for functional safety circuits

This manual does not repeat the complete safety instructions of the drive but only includes

the instructions related to the scope of this manual.

Safety instructions 7

Only a qualified electrician who has appropriate knowledge on functional, machine, and

process safety is allowed to install, start up and maintain the safety circuit. All user-made

changes are on the user's responsibility.

WARNING! Always test the operation of the safety circuit according to its

acceptance test procedure at the start-up and after any changes to the safety

circuit.

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 electrician, do not do installation or maintenance work.

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 electrician, 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. 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.

• Make sure that re-connection is not possible. Lock out and tag out.

• Disconnect any 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.

• Use a multimeter with an impedance greater than 1 Mohm.

• Make sure that the voltage between the drive input power terminals (L1, L2, L3)

and the grounding (PE) busbar is close to 0 V.

• If you have a permanent magnet motor connected to the drive, make sure that the

voltage between the drive output terminals (T1/U, T2/V, T3/W) and the grounding

(PE) busbar is close to 0 V.

6. Ask the person in control of the electrical installation work for a permit to work.

8 Safety instructions

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

The manual applies to ACS880-07/17/17LC/37/37LC drives which have the option:

Emergency stop, stop category 1 with main contactor/breaker, with safety relays (option

+Q952).

For the option +Q952, ABB installs the FIO-01 digital I/O extension module (option +L501)

to the drive.

Target audience

The manual is intended for people who install, start up, 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.

Introduction to the manual 9

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 acceptance test to ensure that the implemented system meets the safety requirements. Instruc-

tions for the acceptance test can be found in this manual.

Document the acceptance test procedure. Guidelines for the acceptance test report can be found 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

3AXD50000020436ACS880-17 drives (160 to 3200 kW) hardware manual

3AXD50000035158ACS880-17 drives (45 to 400 kW) hardware manual

3AXD50000250295ACS880-17LC hardware manual

3AXD50000020437ACS880-37 drives (160 to 3200 kW) hardware manual

3AXD50000035159ACS880-37 drives (45 to 400 kW) hardware manual

3AXD50000251407ACS880-37LC 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

3AXD10000102417Functional safety design tool user’s manual

Safety

3AUA0000048753Functional safety; Technical guide No. 10 Safety and functional safety; A general guide

1SFC001008B0201Safety and functional safety; A general guide

www.abb.com/safetyABB Safety information and solutions

Options

3AUA0000085685ACX-AP-x assistant control panels user’s manual

Manuals and quick guides for I/O extension modules, fieldbus adapters, etc.

Other documents

Delivered with the

drive

Circuit diagrams

Delivered with the

drive

Part lists

10 Introduction to the manual

CodeManual

Safety data report (if the safety circuit is application-engineered)

You can find manuals and other product documents in PDF format on the Internet. See

Document Library. For manuals not available in the Document library, contact your local

ABB representative.

For additional ABB safety information and solutions visit http://www.abb.com/safety.

ACS880-17 (45 to 400 kW) manualsACS880-07 (560 to 2800 kW)

manuals

ACS880-07 (45 to 710 kW) manuals

ACS880-37 (45 to 400 kW) manualsACS880-17LC manualsACS880-17 (160 to 3200 kW)

manuals

ACS880-37LC manualsACS880-37 (160 to 3200 kW)

manuals

Introduction to the manual 11

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

Digital inputDI

Digital input interlockDIIL

Emergency stopE-stop

Optional digital I/O extension moduleFIO-01

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)PFD

avg

Average frequency of dangerous failures per hour (IEC 61508)PFH

Performance level. Levels a...e correspond to SIL (EN ISO 13849-1)PL

Relay outputRO

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

Proof test interval. Defines the probabilistic failure rate (PFH or PFD) for the safety

function or subsystem. Performing a proof test at a maximum interval of T1 is 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 T1 values given cannot be regarded

as a guarantee or warranty.

12 Introduction to the manual

Option description

Contents of this chapter

This chapter describes the +Q952 emergency stop option and its settings.

Overview

The option +Q952 corresponds to a controlled stop in accordance with stop category 1

(EN/IEC 60204-1). After the user has given the emergency stop command, the drive first

decelerates the motor(s) to zero speed according to a preset ramp time. Then, the drive

trips the main contactor/breaker which cuts off the input power of the drive.

For the option +Q952, ABB installs the FIO-01 digital I/O extension module (option +L501)

to the drive control board (Slot 1).

Note: Drives with the Prevention of unexpected start-up (POUS) option (+Q957): If the user

activates the POUS function during the emergency stop deceleration ramp, it overrides the

emergency stop function. This activates the Safe torque off (STO) function of the drive

immediately and the motor coasts to a stop. For more information on the POUS safety

function, see Prevention of unexpected start-up (option +Q957) for

ACS880-07/17/17LC/37/37LC drives (3AUA0000119910 [English]).

The design principles of the option +Q952 comply with EN ISO13850.

For a list of related standards and European directives, see section Related standards and

directives.

Operation principle

The figures show a simplified operation principle. Implementation of main contactor/breaker

and charging circuit can vary depending on the product. For a more detailed description,

see the circuit diagrams delivered with the drive.

Option description 13

￭ ACS880-07 drives, frames R6 to R11 and ACS880-17/-37 drives, frame

-Qx

Main circuit

-T1

-Qx

Main circuit

-T1

-A61

24 VDC+

-S61

-K63-K63

-S62-S62

-Qx-Qx

-K61-K61

-A41

XSTO

IN2

OUT

SGND

IN1

IN2

OUT

SGND

IN1

-X969-X969

-A62

-K21.1-K21.1

24 VDC+

-A412.X

RO1

DIO2

-A62-A62

-K21.1-K21.1

-K61-K61

-K63-K63

230 VAC

-Qx-Qx

-K21.1-K21.1

230 VAC

-Qx

-K21.1

230 VAC

-Qx

-K21.1

Inverter control unitA41

Digital I/O extension module FIO-01A412.X

Emergency stop safety relay with delay contactsA61

Extension safety relayA62

Emergency stop buttonS61

Emergency reset button with indicator lightS62

Safety relayK21.1

Timer relayK61

Safety relayK63

Drive moduleT1

Main contactor/breaker (Q2 or Q1)Qx

STO terminal blockX969

Reset circuit1)

OperationStep

Initial status: The drive is in operation and the motor is running.

The user activates emergency stop with the emergency stop button [S61].1

14 Option description

OperationStep

The emergency stop safety relay [A61] switches off the digital input on the digital I/O extension

module [A412.X] of the drive. This gives the emergency stop command.

The emergency stop safety relay [A61] switches off the power for the timer relay [K61].

The break delay counter of the emergency stop safety relay [A61] starts (user-adjustable delay).

The break delay counter of the timer relay [K61] starts (non-user-adjustable delay).

The drive acknowledges the reception of the emergency stop command by energizing the relay output

(RO1) of the digital I/O extension module [A412.X].

The relay output of the extension module [A412.X] re-energizes the timer relay [K61] resetting its

break delay counter. The relay keeps its delayed break contact closed.

Note: If the drive fails to acknowledge the reception of the emergency stop command in 2 seconds,

the main contactor opens and the system is tripped.

The drive decelerates the motor to zero speed in emergency stop deceleration time (parameter setting).4

The break delay counter of the emergency stop safety relay [A61] trips and the delay contact switches

off the power for the extension safety relay [A62].

5 The extension safety relay [A62] switches off the power for the auxiliary safety relay [K21.1] and

auxiliary relay [K63].

The auxiliary safety relay [K21.1] switches off the main contactor/breaker [Qx].

The contact of the auxiliary relay [K63] energizes the emergency stop reset button indicator light

[S62].

Normal operation resumes after the user:

• releases the emergency stop button [S61] to normal (up) position

• resets the emergency stop circuit with the emergency stop reset button [S62] (the user must push

the button for 0.1 - 3 seconds)

• resets the drive (if the drive tripped on a fault).

Option description 15

￭ ACS880-17/37 drives, frame R11

-A61

24 VDC+

-S61

-K63-K63

-S62-S62

-Q2-Q2

-K61-K61

-A41

XSTO

IN2

OUT

SGND

IN1

IN2

OUT

SGND

IN1

-X969-X969

-A62

-K21.2-K21.2

24 VDC+

-A412.X

RO1

DIO2

-A62-A62

-K21.1-K21.1

-K61-K61

-K63-K63-K21.1-K21.1

-Q2-Q2

-K21.1-K21.1

T1- Internal

Supply

-Q2

-K21.1

T1- Internal

Supply

-Q3-Q3

-K21.2-K21.2

230 VAC

-Q3

-K21.2

230 VAC

-K21.2-K21.2-Q3-Q3

Main circuit

-T1

-Q2

-Q3

Main circuit

-T1

-Q2

-Q3

Inverter control unitA41

Digital I/O extension moduleA412.X

Emergency stop safety relay with delay contactsA61

Extension safety relayA62

Emergency stop buttonS61

Emergency reset button with indicator lightS62

Safety relayK21.1

Safety relayK21.2

Timer relayK61

Safety relayK63

Drive moduleT1

Main contactorQ2

Charging contactorQ3

STO terminal blockX969

Reset circuit1)

16 Option description