ABB DCS8 Series Original User Manual Download Page 1

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Options for ABB drives

Original user’s manual

Prevention of unexpected start-up (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

+Q952

+Q963

+Q964

+Q957

Summary of Contents for DCS8 Series

Page 1: ...l 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 ...

Page 2: ... 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 adapte...

Page 3: ...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 di...

Page 4: ...NG 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 ...

Page 5: ...nce 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 introduc...

Page 6: ...e 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 c...

Page 7: ...fety 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 W...

Page 8: ... 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 princ...

Page 9: ...7 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 ...

Page 10: ...unction 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 ac...

Page 11: ...t 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 shielde...

Page 12: ...ly 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 co...

Page 13: ...g 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...

Page 14: ...nformation 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 ...

Page 15: ...n 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...

Page 16: ...0a 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 D...

Page 17: ...ication 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 th...

Page 18: ... 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 Electri...

Page 19: ...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 p...

Page 20: ...ly ABB Automation Products Wallstadter Straße 59 68526 Ladenburg Germany Tel 49 0 6203 71 0 Fax 49 0 6203 71 76 09 www abb com dc drives 504R0301A0090000 504R0301A0090000 Ident No 3ADW000504R0301 Rev C 02 2020 ...

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