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ABB FSO-21, User Manual

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10   Table of contents

Related safety functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   375

Configuring POUS   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   376

How to configure POUS  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   376

How to configure SLS function behavior when drive modulation is lost  . . . . . . . . . . . . . . . .   376

How to configure SLSn with time monitoring if drive modulation is lost during SLS decelera-
tion ramp   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   377
How to configure SLSn with ramp monitoring if drive modulation is lost during SLS decelera-
tion ramp   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   383

Configuring SSM   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   387

How to configure SSM  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   388

Configuring SDI   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   389

How to configure SDI with time monitoring   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   390
How to configure SDI with ramp monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   391
Related safety functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   392

Configuring mute times   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  393

How to determine values for mute time parameters   . . . . . . . . . . . . . . . . . . . . . . . . . . .   393
How to configure limit hit situations  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   394
How to configure mute time for zero speed detection  . . . . . . . . . . . . . . . . . . . . . . . . . .   397
How to configure mute time for SBC speed limit detection   . . . . . . . . . . . . . . . . . . . . . .   398
How to configure mute time for monitoring start   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   399

11. Parameters

Contents of this chapter  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  401
FSO-21 parameters  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  401
Status and control words   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  449

12. Start-up

Contents of this chapter  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  455
Safety considerations  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   455
Checks  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   456

13. Verification and validation

Contents of this chapter  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  457
Verifying the achieved SIL/PL level   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   457
Purpose of the validation testing   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   457
Preconditions for validation testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   458
Validation procedure   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   458

General   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   458
Validation test reports   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   459
Competence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   459
Tools   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   459
Validation of the PROFIsafe connection   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   460
Validation of the safety encoder interface   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   461
Validation of safety functions  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   464
Validation of redundant inputs  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   464
Validation of safety I/O’s   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   465
Validation of the general settings  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   465
Validation of the STO function  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   466

Summary of Contents for FSO-21

Page 1: ... OPTIONS FOR ABB DRIVES FSO 21 safety functions module User s manual ...

Page 2: ...S880 37LC drives hardware manual 3AXD50000251407 ACS880 104 inverter modules hardware manual 3AUA0000104271 ACS880 107 inverter units hardware manual 3AUA0000102519 ACS880 104LC inverter modules hardware manual 3AXD50000045610 ACS880 107LC inverter units hardware manual 3AXD50000196111 DCS880 hardware manual 3ADW000462 Drive firmware manuals and guides ACS880 primary control program firmware manua...

Page 3: ...r s manual FSO 21 safety functions module 3AXD50000015614 Rev H EN Original instructions EFFECTIVE 2022 01 07 2022 ABB All Rights Reserved 1 Safety instructions Table of contents 12 Start up 8 Installation ...

Page 4: ......

Page 5: ...20 Contents 20 Recommended reading 22 Terms and abbreviations 22 Certificates 29 3 Safety information and considerations Contents of this chapter 31 Use of safety functions 31 Meeting the requirements of the Machinery Directive 32 Responsibilities 32 Intentional misuse 32 Safety related parts 32 Limitations of Safe torque off STO function 32 Proof testing 33 Safety separation 33 ACS880 drives with...

Page 6: ...tents of this chapter 53 General 54 Safety function request 54 Acknowledgement methods 55 DC magnetization and drive start modes 56 Ramp monitoring 57 Safety function indications 58 FSO modes 60 FSO states 60 Transitions between FSO modes and states 61 Cascade 62 Mute time feature 64 Safe torque off STO 67 STO function 68 SBC after STO 71 SBC before STO 74 STO with speed limit activated SBC 77 Saf...

Page 7: ...d SLS 172 Variable SLS with time monitoring 173 Variable SLS with ramp monitoring 175 Safe maximum speed SMS 177 SMS function version 1 178 SMS function version 2 179 Prevention of unexpected start up POUS 180 Safe speed monitor SSM 182 SSM with a safe speed estimate 184 Safe direction SDI 186 SDI with correct rotation direction 186 SDI with time monitoring 188 SDI with ramp monitoring 190 SDI tri...

Page 8: ...ta cable between FSO module and drive 289 Power supply connection cables 289 Power supply for the FSE module and safety encoders 289 Ensuring the EMC compatibility 289 Selecting control cables 290 Routing the cables 290 Standard function and wiring examples 291 8 Installation Contents of this chapter 295 Unpacking 296 Examining the delivery 296 Mechanical installation 297 Installing the module ont...

Page 9: ...t 340 How to configure SS1 with ramp monitoring SS1 r 342 How to configure SS1 with speed limit activated SBC 343 How to configure SS1 with speed limit activated SBC SBC before STO 347 Related safety functions 350 Configuring SSE 351 How to configure SSE with immediate STO 351 How to configure SSE with immediate STO SBC after or before STO 353 How to configure SSE with immediate STO with speed lim...

Page 10: ...ons 394 How to configure mute time for zero speed detection 397 How to configure mute time for SBC speed limit detection 398 How to configure mute time for monitoring start 399 11 Parameters Contents of this chapter 401 FSO 21 parameters 401 Status and control words 449 12 Start up Contents of this chapter 455 Safety considerations 455 Checks 456 13 Verification and validation Contents of this cha...

Page 11: ...01 User selectable events for limit hits and special events 501 User selectable events for safety fieldbus failures 504 Auxiliary codes 504 FSO recovery 504 External fault 504 Internal fault 505 Reporting problems and failures 505 15 Maintenance Contents of this chapter 507 Planning 507 Tools 507 Component replacement in the safety circuit 508 Before component replacement 508 Replacing the FSO mod...

Page 12: ... weight 517 Cooling 517 Compatible motor types 518 Speed estimation 518 Ambient conditions 518 Safety functions 519 Safety data 520 General 520 Basic safety data 522 FSE 31 pulse encoder interface module 523 FSO safety calculations guide without PROFIsafe 524 FSO safety calculations guide with PROFIsafe 529 Safety data for some typical configurations 529 Relevant failure modes 531 Response times 5...

Page 13: ... occur Read this chapter before you start the installation Use of warnings 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 The manual uses these warning symbols Electricity warning tells you about hazards from electricity which can cause injury or death or damage to the equipment General warning tells you ab...

Page 14: ...motor from the drive with a safety switch or by other means Disconnect all 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 Me...

Page 15: ...Safety instructions 15 6 Install temporary grounding as required by the local regulations 7 Ask the person in control of the electrical installation work for a permit to work ...

Page 16: ...16 Safety instructions ...

Page 17: ...on needed to use the FSO 21 safety functions module when implementing safety systems The information and examples given are for general use only They do not describe all the necessary details for implementing a safety system The manufacturer of the machinery always remains ultimately responsible for the product safety and compliance with applicable laws ABB does not accept any liability for direct...

Page 18: ... or later Winder control program v1 10 or later PCP ESP control program N5200 v1 1 or later PCP ESP control program SynRM v1 1 1 0 or later Spinning control program v1 0 or later Rod pump control program v1 0 or later Note If you want to use the possibility to switch the motor speed feedback between encoder and estimate ACS880 primary control program version 2 51 or later and FSE 31 revision F or ...

Page 19: ...y encoder together with the FSO 21 module Sections in this manual which describe the safe speed estimate or sections which refer to drive modulating are not applicable to DCS880 Controller stations For example the following controller stations are supported Check the compatibility of the controller station in its manual ABB AC500 S Safety PLC For more information see AC500 S Safety User Manual 3AD...

Page 20: ...plication Read the manual before starting work on the safety application You must know the fundamentals of safety technology electricity wiring electrical components and electrical schematic symbols Purpose of the manual The manual explains how to install the FSO safety functions module and configure and commission the supported safety functions It describes how to meet and maintain safety life cy...

Page 21: ...l safe S7 PLC as well as fault tracing tips Chapter Planning for installation page 287 gives instructions and references to instructions in other manuals for planning the safety system installation as well as the requirements for installation in the applicable safety standards Chapter Installation page 295 gives examples of how to connect the FSO module to the ACS880 DCS880 Chapter Installation ch...

Page 22: ...13849 1 Safety of machinery Safety related parts of control systems Part 1 General principles for design EN IEC 62061 Safety of machinery Functional safety of safety related electrical electronic and programmable electronic control systems EN 60204 1 Safety of machinery Electrical equipment of machines Part 1 General requirements PROFIsafe System Description Safety Technology and Application Versi...

Page 23: ...rk eg a fieldbus The communication with the module is activated with a drive parameter Controller Control system with bus initiative master In PROFINET IO terminology controller stations are also called active stations Control word 16 bit word from controller to device with bit coded control signals sometimes called the Command word CRC Cyclic redundancy check Cyclic communication Communication in...

Page 24: ...meter drive parameter group 50 FB module Fieldbus adapter module FPNO 21 or FENA 21 FENA 21 Optional Ethernet adapter module for EtherNet IP Modbus TCP and PROFINET IO protocols FIT Failure in time 1E 9 hours Expected failure rate of semiconductors and other electronic devices IEC 61508 FPNO 21 PROFINET fieldbus adapter module FSE 31 Pulse encoder interface module which can be used in safety appli...

Page 25: ... To achieve a safe state the STO function must be activated MTTFD Mean time to dangerous failure The total number of life units the number of dangerous undetected failures during a particular measurement interval under stated conditions EN ISO 13849 1 N A Not applicable NC Normally closed Break contact Normally closed contacts disconnect the circuit when the relay is energized the circuit is conne...

Page 26: ...O reacts after receiving a request Usually this is not the same as the time from the request to the safe state of the machine application See also term Safety function response time SFRT on page 26 Risk Combination of the probability of occurrence of harm and the severity of that harm Safe state STO activated The STO circuit in the drive is open Note When the drive STO is activated in the POUS fun...

Page 27: ...re used in SS1 SLS varSLS and SDI functions SBC Safe brake control SC Systematic capability IEC 61508 Scaling speed A user defined value that the FSO module uses as a speed reference point in ramp time calculations See parameter 200 202 SAR speed scaling on page 404 SDI Safe direction SELV Safety extra low voltage SFF Safe failure fraction IEC 61508 SFRT Safety function response time see page 26 S...

Page 28: ...define the probabilistic failure rate PFH or PFDavg 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 See also section Proof tests on page 512 Tm See Mission time TP Test pulse Term diagnostic pulse is used in this manual TWCDT Total wo...

Page 29: ...ates TÜV Nord certificate for the FSO 21 and ACS880 DCS880 drive series can be found in ABB Library Check the validity of the certificate with a specific drive variant from the ABB Library λs Safe failure rate Term Abbreviation Description ...

Page 30: ...Isafe_V2 functionality on PROFINET IO Test Report Number PS087 3 Authorized Test Laboratory SIEMENS AG Fürth Germany The tests were executed in accordance with the following documents PROFIsafe Test Specification for F Slaves F Devices and F Hosts Version 2 1 March 2007 This certificate is granted according to the document Framework for testing and certification of PROFIBUS and PROFINET products F...

Page 31: ...sure that the functional safety of the machine is maintained in situations where the safety option does not provide protection for example during commissioning system maintenance fault tracing or decommissioning Use of safety functions To make sure that the application where FSO and its safety functions are used is safe to use and fulfills all relevant safety requirements it is necessary to take i...

Page 32: ...lities As a component manufacturer ABB is only responsible for the safety and conformity of their manufactured products not of the systems where these products are used If you detect any failure in safety functions contact your local ABB representative Intentional misuse Use the FSO and FSE modules according to the instructions given in the user s manuals ABB is not responsible for any damage caus...

Page 33: ...echanical actuator for example a brake could lead up to an undetected fault and a possible loss of the load control Safety separation The FSO module and the drive Safe torque off STO channel function are safety relevant and the rest of the drive is considered as not safety relevant for example the drive regular I O cannot be used for requesting safety functions on the FSO WARNING The Safe torque o...

Page 34: ...34 Safety information and considerations ...

Page 35: ...unexpected event occurs that requires a safe reaction of the safety related control system The main purpose of the FSO module is to make the systems applications safe to use It can be the main safety logic for the safety system or it can be part of a larger safety related control system as a subsystem The FSO module can be used in applications where EN ISO 13850 is used This standard gives the req...

Page 36: ...ey those requirements when he she implements safety functions with the FSO module FSO module and safety system components Example figure of a safety system with the FSO 21 safety functions module the ACS880 01 drive a safety PLC an FB module an FSE module switches and buttons The FSO safety functions module is an option for the ACS880 DCS880 drives The Safe torque off STO function is a standard fe...

Page 37: ...le with the new revision If you replace an FSO 12 module with an FSO 21 module you have to re configure the FSO module and safety functions Each time you make any changes in the safety system you must do the acceptance test to each safety function using the checklists described in chapter Verification and validation Note Due to an update in functionality related to a situation where drive modulati...

Page 38: ...ng points for drives with other control units may vary 5 FSO grounding screw grounds the electronics 6 FSO status LEDs see section Status LEDs on page 489 7 Input output status LEDs one for each I O connector The LEDs are in two rows above the corresponding two rows of I O connectors The LED is lit if the state of the corresponding I O is ON 24 V in the input or output The data shown by LEDs is on...

Page 39: ...tions 4 redundant or 8 single digital inputs or combinations of redundant and single inputs Possible redundant pairs X113 1 X114 1 X113 2 X114 2 X113 3 X114 3 and X113 4 X114 4 3 redundant or 6 single digital outputs or combinations of redundant and single outputs Possible redundant pairs X113 7 X114 7 X113 8 X114 8 and X113 9 X114 9 two 24 V DC reference outputs with configurable diagnostic pulse...

Page 40: ...and must be rebooted for rebooting instructions see section FSO recovery on page 504 The FSO module checks on every boot that the drive has the same configuration as the FSO module If the configurations do not match the FSO module keeps the STO active When the FSO module is configured with the Drive composer pro the tool will do a sanity check for the FSO configuration to make sure that it is plau...

Page 41: ...ternal failure situations the FSO module activates the STO function I O The FSO module supports input and output redundancy The FSO module provides an option for applying diagnostic pulsing for its inputs and outputs When applied the pulsing enables the FSO diagnostics to detect cable failures as follows Inputs Open circuiting and short circuiting failures are detected with diagnostic pulsing The ...

Page 42: ...ion for the control of a safety device Acknowledgement Safety functions have four acknowledgement methods for entering the Operational state at power up or after a safety function request is removed Manual recommended The user must first acknowledge the FSO locally from the FSO I O to allow the drive to restart Automatic The FSO grants the drive permission to restart after a safety function reques...

Page 43: ...d a safety encoder are used in a safety function with a SIL PL requirement the safety encoder must be SIL PL classified The user must make sure that the SIL PL capability of the safety encoder and the complete safety function meets the required SIL PL With ACS880 two safety functions SDI and STO with speed limit activated SBC require a safety encoder With DCS880 the safe speed estimate cannot be u...

Page 44: ...nctions are configured See chapter Safety functions for more information on the difference between the measured speed feedback encoder and safe speed estimate Note With safe speed estimate the FSO module and the drive motor control have an independent motor model of their own The accuracy of these two speed estimates can differ from each other especially in the low speed region Safe speed estimate...

Page 45: ...ase For example the motor type and number of pole pairs 5 The drive and motor shall be dimensioned considering the application for example inertia operating environment etc The dimensioning shall be such that all functions can be performed without exceeding the specified operating limits of the drive and motor 6 The drive shall be dimensioned considering the motor and vice versa for example nomina...

Page 46: ...shows 0 rpm Because of this main principle it is a must that the motor speed starts to slow down by coasting when the power is switched off If the motor is not decelerating fast enough by coasting the rotation must be stopped with external device for example with a safe brake It is not allowed to use the safe speed estimation with an external active load that can accelerate the motor shaft For exa...

Page 47: ...or slip is again in its maximum value Because of the torque direction FSO speed estimates are below the actual motor speed amount of the slip After the FSO safe speed estimates reach 0 rpm they begin to show reverse negative motor speed due to the negative motor slip The FSO module starts to compare the safe speed estimation to the negative SLS trip limit value Because the trip limit is much lower...

Page 48: ...ces to the detailed descriptions For a description of the dependencies between the safety functions see section Dependencies between safety functions on page 193 Safe torque off STO This safety function activates the STO function in the drive this is opens the STO circuit in the drive The motor coasts to a stop stop category 0 See section STO function on page 68 The FSO module activates the STO fu...

Page 49: ...usly STO function and SSE with immediate STO In these safety functions you can configure the SBC function to be activated before at the same time with or after the drive STO function See sections SBC after STO on page 71 SBC before STO on page 74 SSE with immediate STO SBC after STO on page 109 and SSE with immediate STO SBC before STO on page 112 When you use an encoder you can also configure the...

Page 50: ...S This safety function prevents the motor from exceeding user defined speed limits With the variable SLS function it is possible to scale down the SLS limits with a safety PLC via PROFIsafe communication See section Variable Safely limited speed SLS on page 172 and chapter PROFIsafe Safe maximum speed SMS This safety function is used to protect the machine from too high speeds frequencies You can ...

Page 51: ... safety application See section Safe direction SDI on page 186 Safe acceleration range SAR This safety function provides safe deceleration ramp monitoring for other safety functions FSO module has two different SAR functions SAR0 and SAR1 SAR0 and SAR1 functions behave in the same way but they can be configured to work differently based on the application needs SAR0 parameters are used with the SS...

Page 52: ...52 Overview ...

Page 53: ...op category 1 With time SS1 t or ramp monitoring SS1 r 79 Safe stop emergency SSE Stop category 0 or 1 With immediate STO or emergency ramp with time or ramp monitoring 106 Safe brake control SBC With STO SSE and SS1 functions 49 Safely limited speed SLS With time or ramp monitoring 140 Variable Safely limited speed SLS Only with PROFIsafe 172 Safe maximum speed SMS Function permanently on off Two...

Page 54: ...input it is possible to activate up to two separate safety functions A request activates both functions simultaneously For the execution order see section Priorities between safety functions page 193 Note The FSO module does not react to activation requests of the safety functions during the boot Safe direction SDI With time or ramp monitoring Only with an encoder 186 ID Description A Normal reque...

Page 55: ...l completion of a safety function when the safety function request has been removed The user must do this manually by pressing the acknowledgement button You can connect only one acknowledgement button to the FSO module The acknowledgement button must be of type normally closed NC The acknowledgement button is connected like a normal safety input 24 V in the input is the standby negative state and...

Page 56: ...the same acknowledgement When several safety functions are active at the same time the priorities described in section Priorities between safety functions page 193 apply Note If the FSO module is rebooted after a safety function request has been removed but before it has been acknowledged the FSO reboot acknowledges the safety function DC magnetization and drive start modes The correct operation o...

Page 57: ...AR0 ramp time to zero C Maximum deceleration time from the Scaling speed to zero Configured for each SARn ramp n 0 1 separately For example for SAR0 parameter SARx 12 SAR0 max ramp time to zero D Initial allowed range for the SARn ramp value of parameter SARx 02 SAR initial allowed range This parameter moves the location of the maximum ramp forward on the time axis when monitoring is started that ...

Page 58: ... a fault when the drive is modulating see FSO premature POUS on page 492 FSO digital output indication FSO digital outputs can be configured for indication or for controlling eg safety door locking unlocking Digital output indications for the safety functions are explained in connection with the safety function descriptions in chapter Safety functions in Configuring I O on page 319 and in Paramete...

Page 59: ...atus bit octet 0 bit 6 SBC_active POUS active state is indicated immediately when requested from an input POUS 21 POUS output Ramp monitoring SAR0 and SAR1 see section Configuring SAR on page 361 is not indicated The FSO module switches off the digital output indications SSE SS1 and POUS functions when the function is acknowledged Stop completed indications are activated when the stopping function...

Page 60: ...t states see section FSO states on page 60 depending on the status of safety functions and the safety fieldbus communication Indicated with a green RUN LED Fail safe There is a failure in the FSO The drive STO is active Indicated with a red STATUS FAULT LED You have to reboot the FSO to exit the Fail safe mode See section Transitions between FSO modes and states on page 61 Configuration Parameters...

Page 61: ...erational STO inactive FSO running Operational STO active POUS active FSO running Safe STO active FSO running Fail safe STO active I O FSO or communication fault detected FSE module or encoder failure situation can also cause the Fail safe transition See parameter S_ENCGEN 11 Power down STO active Start up STO active Configuration STO active Fail safe STO active Safe STO active Operational STO ina...

Page 62: ...e Operational state the drive STO function is inactive except when the POUS function is active the drive STO function is also active Note When the drive is connected to a safety PLC via the PROFIsafe over PROFINET communication bus see the states diagrams in section FSO module modes and states on page 212 in chapter PROFIsafe Cascade It is possible to cascade up to six FSO modules into a daisy cha...

Page 63: ... safety function indication both in the master and the follower FSO modules Use the completed output of the cascaded safety function for the indication in this example output X113 7 is used to indicate SSE completed You must configure all follower FSO modules to use the automatic acknowledgement method The master FSO module can use any acknowledgement method The acknowledgement always starts from ...

Page 64: ...ous transients in safe speed estimate you can suspend speed monitoring with mute time to prevent unnecessary trips in the safety system The transient mute time can be set to cover the transient situation with the parameter FSOGEN 31 Transient mute time This transient mute time covers limit hits monitoring start and zero speed limits It is also possible to use function specific mute times for limit...

Page 65: ...with the parameters FSOGEN 31 Transient mute time for safety function limit hits FSOGEN 32 Zero speed delay time for zero speed FSOGEN 33 Monitoring start delay for monitoring start When the safety encoder is used function specific mute times have no effect even if they are enabled If the switching from encoder to safe speed estimate is allowed by parameter S_ENCGEN 11 FSE diagnostic failure react...

Page 66: ...Monitoring start situation 3 Limit hit situation 4 Zero speed situation Monitoring start delay D Limit hit E Zero speed delay time F Without encoder Function specific mute times disabled FSOGEN 31 FSOGEN 31 FSOGEN 31 Without encoder Function specific mute times enabled FSOGEN 31 Function specific mute times FSOGEN 31 With encoder FSOGEN 33 FSOGEN 31 FSOGEN 32 ...

Page 67: ...ifferent versions of the STO function separately without and with an encoder For more information on the STO function in the ACS880 DCS880 drives see the corresponding drive hardware manual WARNING For the encoderless mode you have to set parameters STO 14 and SBC 13 so that the motor has enough time to stop from full speed when modulation is stopped Note If the SSE is cascaded STO activation also...

Page 68: ... the motor has stopped fly start You can use this feature only in certain applications This parameter is relevant only when an external request activates the STO function Step Description 1 The STO request is received for example from the I O The FSO activates the drive STO function and starts counters for times A and B STO active indication parameter STO output STO 21 goes on 2 After time B has e...

Page 69: ...vates the STO function Step Description 1 The STO request is received for example from the I O The FSO activates the drive STO function and starts a counter for time B STO active indication parameter STO output STO 21 goes on 2 After time B has elapsed the acknowledgement becomes allowed as soon as the STO request has been removed step 4 Note The acknowledgement becomes allowed already at the zero...

Page 70: ...70 Safety functions 5 After the acknowledgement the STO is deactivated The indications STO output STO 21 and STO completed output STO 22 go off Step Description ...

Page 71: ...s activated while the motor is still rotating B SBC time to zero speed parameter SBC 13 Time from the SBC activation to the moment when the safety function is completed and the STO completed indication parameter STO 22 goes on You must set this to the estimated time in which the motor brakes to a stop from the maximum speed C Restart delay after STO parameter STO 13 Time from the STO activation to...

Page 72: ...control is given back to the drive which controls the brake from now on The indications STO output STO 21 and STO completed output STO 22 go off A Zero speed with encoder parameter FSOGEN 52 Speed limit at which the motor has stopped the safety function is completed and STO completed indication parameter STO 22 goes on B SBC delay parameter SBC 12 Time from the activation of the drive STO function...

Page 73: ... indication parameter STO output STO 21 goes on 2 After time C has elapsed the acknowledgement becomes allowed as soon as the STO request has been removed step 5 3 After time B has elapsed the FSO activates the SBC function brake Note If zero speed limit A is reached before time B has elapsed the FSO activates the SBC function immediately when the motor has stopped 4 The motor speed reaches the ze...

Page 74: ...unction brake In this case the value is negative and the FSO activates the SBC before the drive STO If the value is zero the FSO activates the SBC and drive STO functions at the same time B SBC time to zero speed parameter SBC 13 Time from the SBC activation to the moment when the safety function is completed and the STO completed indication parameter STO 22 goes on The acknowledgment becomes allo...

Page 75: ...ime A has elapsed the FSO activates the drive STO 4 After time B has elapsed the FSO module defines the motor as stopped and the STO completed indication goes on The acknowledgement becomes allowed as soon as the STO request has been removed step 5 5 The STO request is removed 6 After the acknowledgement the STO and SBC functions are deactivated and the control is given back to the drive which con...

Page 76: ...for example from the I O The FSO activates the SBC function brake and starts a counter for time B STO active indication parameter STO output STO 21 goes on 2 After time C has elapsed the SBC starts to brake the motor 3 After time B has elapsed the FSO activates the drive STO 4 The motor speed reaches the zero speed limit A the FSO module defines the motor as stopped and the STO completed indicatio...

Page 77: ...meter FSOGEN 52 Speed limit at which the motor has stopped the safety function is completed and the STO completed indication parameter STO 22 goes on The acknowledgment becomes allowed C Restart delay after STO parameter STO 13 Time from the STO activation to the moment when the acknowledgment becomes allowed With this parameter you can allow a restart of the drive before the motor has stopped fly...

Page 78: ...ed limit A and the FSO activates the SBC function brake 4 The motor speed reaches the zero speed limit B the FSO module defines the motor as stopped and the STO completed indication goes on The acknowledgement becomes allowed despite of value C as soon as the STO request has been removed step 5 5 The STO request is removed 6 After the acknowledgement the STO and SBC functions are deactivated and t...

Page 79: ...imit s the FSO activates the STO function and the motor coasts to a stop The SS1 function uses SAR1 parameters to define and or monitor the stop ramp When you use the SBC function with the SS1 function you can configure the SBC and drive STO combination to be activated at a user defined speed limit while ramping down to zero speed You can also define a delay so that the SBC is activated first at t...

Page 80: ...or STO parameter SS1 14 Time after which the FSO activates the STO function regardless of the motor speed B Zero speed parameter FSOGEN 51 Speed limit for activating the drive STO function The safety function is completed and the SS1 completed indication parameter SS1 22 goes on C Response time depends on system configuration see page 532 Drive STO state indication SS1 request Motor speed Time SS1...

Page 81: ...ection Safe torque off STO on page 67 also the SBC is activated not shown in the figure If the STO SBC delay parameter SBC 12 is negative the SBC is activated here and the drive STO after this delay If the STO SBC delay is positive or zero the SBC and drive STO functions are activated at the same time The SS1 completed indication goes on after the delay defined with parameter SBC 13 has elapsed fr...

Page 82: ...FSOGEN 52 Speed limit for activating the drive STO function The safety function is completed and the SS1 completed indication parameter SS1 22 goes on The acknowledgment becomes allowed C Response time depends on system configuration see page 532 Drive STO state indication SS1 request Motor speed Time SS1 state indication 1 2 5 3 A B C 3b SS1 completed indication SS1 14 4 Safe torque off STO ...

Page 83: ...tep 4 Note If the SBC is configured in the STO function see section Safe torque off STO on page 67 also the SBC is activated not shown in the figure If the STO SBC delay parameter SBC 12 is negative the SBC is activated here and the drive STO after this delay If the STO SBC delay is positive or zero the SBC and drive STO functions are activated at the same time Note You can define an extra delay p...

Page 84: ...eed estimate A Zero speed parameter FSOGEN 51 Speed limit for activating the drive STO function The safety function is completed and the SS1 completed indication parameter SS1 22 goes on The acknowledgment becomes allowed B Response time depends on system configuration see page 532 Ramp monitoring limits Drive STO state indication SS1 request Motor speed Time SS1 state indication 1 2 5 A B SS1 com...

Page 85: ... SS1 22 goes on and the acknowledgement becomes allowed as soon as the SS1 request has been removed step 4 Note If the SBC is configured in the STO function see section Safe torque off STO on page 67 also the SBC is activated not shown in the figure If the STO SBC delay parameter SBC 12 is negative the SBC is activated here and the drive STO after this delay If the STO SBC delay is positive or zer...

Page 86: ...ted ramp monitoring is stopped and the SS1 completed indication parameter SS1 22 goes on The acknowledgment becomes allowed B Response time depends on system configuration see page 532 Ramp monitoring limits Drive STO state indication SS1 request Motor speed Time SS1 state indication 1 2 5 A B SS1 completed indication 3 2b SAR1 monitoring 4 Safe torque off STO ...

Page 87: ...TO 21 goes on The SS1 completed output indication parameter SS1 22 goes on and the acknowledgement becomes allowed as soon as the SS1 request has been removed step 4 Note If the SBC is configured in the STO function see section Safe torque off STO on page 67 also the SBC is activated not shown in the figure If the STO SBC delay parameter SBC 12 is negative the SBC is activated here and the drive S...

Page 88: ...e and drive STO functions while ramping B SS1 t delay for STO parameter SS1 14 Time after which the FSO activates the STO function regardless of the motor speed C SBC time to zero parameter SBC 13 Time from the SBC activation to the moment when the safety function is completed and the SS1 completed indication parameter SS1 22 goes on The acknowledgment becomes allowed You must set this to the esti...

Page 89: ...th speed limit activated SBC SBC before STO on page 96 STO active indication parameter STO output STO 21 goes on when STO is activated The FSO starts a counter for time C Note You can define an extra delay parameter SS1 15 before the FSO activates the SBC and drive STO functions not shown in the figure 3b If the drive has not ramped down fast enough when time B has elapsed the FSO activates the ST...

Page 90: ... function is completed and the SS1 completed indication parameter SS1 22 goes on The acknowledgment becomes allowed C SS1 t delay for STO parameter SS1 14 Time after which the FSO activates the STO function regardless of the motor speed D Response time depends on system configuration see page 532 Drive STO state indication SS1 request Motor speed Time SS1 state indication 1 6 2 5 SBC output 3 A D ...

Page 91: ... SS1 with speed limit activated SBC SBC before STO on page 96 STO active indication parameter STO output STO 21 goes on when STO is activated Note You can define an extra delay parameter SS1 15 before the FSO activates the SBC and drive STO functions not shown in the figure 3b If the drive has not ramped down fast enough when time C has elapsed the FSO activates the STO function See section Safe t...

Page 92: ...ctions while ramping B SBC time to zero parameter SBC 13 Time from the SBC activation to the moment when the safety function is completed and the SS1 completed indication parameter SS1 22 goes on The acknowledgment becomes allowed You must set this to the estimated time in which the motor brakes to a stop from the maximum speed C Response time depends on system configuration see page 532 Ramp moni...

Page 93: ...e section SS1 with speed limit activated SBC SBC before STO on page 96 STO active indication parameter STO output STO 21 goes on when STO is activated The FSO starts a counter for time B Note You can define an extra delay parameter SS1 15 before the FSO activates the SBC and drive STO functions not shown in the figure 3b If the motor speed hits a ramp monitoring limit the FSO activates the STO fun...

Page 94: ... motor as stopped The safety function is completed the ramp monitoring is stopped and the SS1 completed indication parameter SS1 22 goes on The acknowledgment becomes allowed C Response time depends on system configuration see page 532 Ramp monitoring limits Drive STO state indication SS1 request Motor speed Time SS1 state indication 1 6 2 5 SBC output 3 A C SS1 completed indication SAR1 monitorin...

Page 95: ...mit activated SBC SBC before STO on page 96 STO active indication parameter STO output STO 21 goes on when STO is activated Note You can define an extra delay parameter SS1 15 before the FSO activates the SBC and drive STO functions not shown in the figure 3b If the motor speed hits a ramp monitoring limit the FSO activates the STO function See section Safe torque off STO on page 67 for more infor...

Page 96: ...ter SBC 15 Speed limit below which the FSO activates the SBC brake B SS1 t delay for STO parameter SS1 14 Time after which the FSO activates the STO function regardless of the motor speed C SBC delay parameter SBC 12 Time from the activation of the SBC function to the moment when the FSO activates the drive STO function D SBC time to zero parameter SBC 13 Time from the SBC activation to the moment...

Page 97: ...activation step 4 3b If the drive has not ramped down fast enough when time B has elapsed the FSO activates the STO function See section Safe torque off STO on page 67 for more information on how to configure the STO function 4 After time C has elapsed the FSO activates the drive STO function STO active indication parameter STO output STO 21 goes on when STO is activated 5 The SS1 request is remov...

Page 98: ...edgment becomes allowed C SS1 t delay for STO parameter SS1 14 Time after which the FSO activates the STO function regardless of the motor speed D SBC delay parameter SBC 12 Time from the activation of the SBC function to the moment when the FSO activates the drive STO function E Response time depends on system configuration see page 532 Drive STO state indication SS1 request Motor speed Time SS1 ...

Page 99: ...p 4 3b If the drive has not ramped down fast enough when time C has elapsed the FSO activates the STO function See section Safe torque off STO on page 67 for more information on how to configure the STO function 4 After time D has elapsed the FSO activates the drive STO function STO active indication parameter STO output STO 21 goes on when STO is activated 5 The motor speed reaches the zero speed...

Page 100: ...12 Time from the activation of the SBC function to the moment when the FSO activates the drive STO function C SBC time to zero parameter SBC 13 Time from the SBC activation to the moment when the safety function is completed and the SS1 completed indication parameter SS1 22 goes on The acknowledgment becomes allowed You must set this to the estimated time in which the motor brakes to a stop from t...

Page 101: ...cts also the STO activation step 4 3b If the motor speed hits a ramp monitoring limit the FSO activates the STO function See section Safe torque off STO on page 67 for more information on how to configure the STO function 4 After time B has elapsed the FSO activates the drive STO function STO active indication parameter STO output STO 21 goes on when STO is activated 5 The SS1 request is removed 6...

Page 102: ...pped and the SS1 completed indication parameter SS1 22 goes on The acknowledgment becomes allowed C SBC delay parameter SBC 12 Time from the activation of the SBC function to the moment when the FSO activates the drive STO function D Response time depends on system configuration see page 532 Ramp monitoring limits Drive STO state indication SS1 request Motor speed Time SS1 state indication 1 7 2 6...

Page 103: ... motor speed hits a ramp monitoring limit the FSO activates the STO function See section Safe torque off STO on page 67 for more information on how to configure the STO function 4 After time C has elapsed the FSO activates the drive STO function STO active indication parameter STO output STO 21 goes on when STO is activated 5 The motor speed reaches the zero speed limit B the FSO defines the motor...

Page 104: ...e operational STO cascading is not activated in this case The completed indication of the STO function is not indicated STO 22 instead the SS1 completed indication SS1 22 is activated Otherwise STO function and SBC if in use behaves as configured With safety encoder The lost of modulation does not affect to the behaviour of these functions when they are used with safety encoder See the behaviour i...

Page 105: ...mp monitoring goes off See section Safe torque off STO on page 67 for more information on how to configure the STO function Note If STO is used in cascaded system see Cascade on page 62 it will not be activated in the whole system in this case Note SS1 completed indication SS1 22 is used instead of STO completed indication STO 22 in this case Note If the SBC is configured in the STO function also ...

Page 106: ...s SAR0 parameters to monitor and or define the emergency ramp Drive ramp parameters cannot be used When you use the SBC function with the SSE function you can configure the SBC and drive STO combination to be activated at a user defined speed limit while ramping down to zero speed You can also define a delay so that the SBC is activated first at the user defined speed limit and the drive STO after...

Page 107: ...tep Description 1 The SSE request is received for example from the I O The FSO activates the drive STO function and starts a counter for time A SSE active indication SSE output SSE 21 and STO output STO 21 go on 2 After time A has elapsed the FSO module defines the motor as stopped and the SSE completed indication goes on The acknowledgement becomes allowed as soon as the SSE request has been remo...

Page 108: ...ut SSE 21 and STO output STO 21 go on 2 The motor speed reaches the zero speed limit A the FSO defines the motor as stopped and the SSE completed indication goes on The acknowledgement becomes allowed as soon as the SSE request has been removed step 3 3 The SSE request is removed 4 After the acknowledgement the SSE and STO functions are deactivated and the control is given back to the drive The in...

Page 109: ...he FSO activates the SBC after the drive STO If the value is zero the FSO activates the SBC and drive STO functions at the same time Note It is possible to set the SBC delay so that the SBC is activated while the motor is still rotating B SBC time to zero speed parameter SBC 13 Time from the SBC activation to the moment when the safety function is completed and the SSE completed indication paramet...

Page 110: ...ts a counter for time B 3 After time B has elapsed the FSO module defines the motor as stopped and the SSE completed indication goes on The acknowledgement becomes allowed as soon as the SSE request has been removed step 4 4 The SSE request is removed 5 After the acknowledgement the SSE STO and SBC functions are deactivated and the control is given back to the drive which controls the brake from n...

Page 111: ...STO and starts a counter for time B SSE active indication SSE output SSE 21 and STO output STO 21 go on 2 After time B has elapsed the FSO activates the SBC function brake Note If speed limit A is reached before time B has elapsed the FSO activates the SBC immediately when the motor has stopped 3 The motor speed reaches the zero speed limit A the FSO module defines the motor as stopped and the SSE...

Page 112: ...n the FSO activates the SBC function brake In this case the value is negative and the FSO activates the SBC before the drive STO If the value is zero the FSO activates the SBC and drive STO functions at the same time B SBC time to zero speed parameter SBC 13 Time from the SBC activation to the moment when the safety function is completed and the SSE completed indication parameter SSE 22 goes on Th...

Page 113: ...elapsed the FSO activates the drive STO function 4 After time B has elapsed the FSO module defines the motor as stopped and the SSE completed indication goes on The acknowledgement becomes allowed as soon as the SSE request has been removed step 5 5 The SSE request is removed 6 After the acknowledgement the SSE STO and SBC functions are deactivated and the control is given back to the drive which ...

Page 114: ...he I O The FSO activates the SBC and starts a counter for time B SSE active indication SSE output SSE 21 and STO output STO 21 go on 2 After time C has elapsed the SBC starts to brake the motor 3 After time B has elapsed the FSO activates the drive STO function 4 The motor speed reaches the zero speed limit A the FSO module defines the motor as stopped and the SSE completed indication goes on The ...

Page 115: ...scription 1 The SSE request is received for example from the I O The FSO activates the drive STO function SSE active indication SSE output SSE 21 and STO output STO 21 go on 2 The motor speed goes below the SBC speed limit A and the FSO activates the SBC function brake 3 The motor speed reaches the zero speed limit B the FSO module defines the motor as stopped and the SSE completed indication goes...

Page 116: ...e after which the FSO activates the STO function regardless of the motor speed B Zero speed parameter FSOGEN 51 Speed limit for activating the drive STO function The safety function is completed and the SSE completed indication parameter SSE 22 goes on The acknowledgment becomes allowed C Response time depends on system configuration see page 532 Drive STO state indication SSE request Motor speed ...

Page 117: ...ivated not shown in the figure If the STO SBC delay parameter SBC 12 is negative the SBC is activated here and the drive STO after this delay If the STO SBC delay is positive or zero the SBC and drive STO functions are activated at the same time The SSE completed indication goes on after the delay defined with parameter SBC 13 has elapsed from the SBC activation Note You can define an extra delay ...

Page 118: ...FSOGEN 52 Speed limit for activating the drive STO function The safety function is completed and the SSE completed indication parameter SSE 22 goes on The acknowledgment becomes allowed C Response time depends on system configuration see page 532 Drive STO state indication SSE request Motor speed Time SSE state indication 1 2 5 3 A B C 3b SSE completed indication 4 SSE 15 Safe torque off STO ...

Page 119: ...ee section Safe torque off STO on page 67 also the SBC is activated not shown in the figure If the STO SBC delay parameter SBC 12 is negative the SBC is activated here and the drive STO after this delay If the STO SBC delay is positive or zero the SBC and drive STO functions are activated at the same time Note You can define an extra delay parameter SSE 16 before the FSO activates the drive STO an...

Page 120: ...eed parameter FSOGEN 51 Speed limit for activating the drive STO function The safety function is completed ramp monitoring is stopped and the SSE completed indication parameter SSE 22 goes on The acknowledgment becomes allowed B Response time depends on system configuration see page 532 Ramp monitoring limits Drive STO state indication SSE request Motor speed Time SSE state indication 1 2 5 A B SS...

Page 121: ... acknowledgement becomes allowed as soon as the SSE request has been removed step 4 Note If the SBC is configured in the STO function see section Safe torque off STO on page 67 also the SBC is activated not shown in the figure If the STO SBC delay parameter SBC 12 is negative the SBC is activated here and the drive STO after this delay If the STO SBC delay is positive or zero the SBC and drive STO...

Page 122: ...eted ramp monitoring is stopped and the SSE completed indication parameter SSE 22 goes on The acknowledgment becomes allowed B Response time depends on system configuration see page 532 Ramp monitoring limits Drive STO state indication SSE request Motor speed Time SSE state indication 1 2 5 A B SSE completed indication 3 2b SAR0 monitoring 4 Safe torque off STO ...

Page 123: ...TO 21 goes on The SSE completed indication goes on and the acknowledgement becomes allowed as soon as the SSE request has been removed step 4 Note If the SBC is configured in the STO function see section Safe torque off STO on page 67 also the SBC is activated not shown in the figure If the STO SBC delay parameter SBC 12 is negative the SBC is activated here and the drive STO after this delay If t...

Page 124: ...and drive STO functions while ramping B SSE delay for STO parameter SSE 15 Time after which the FSO activates the drive STO function regardless of the motor speed C SBC time to zero parameter SBC 13 Time from the SBC activation to the moment when the safety function is completed and the SSE completed indication parameter SSE 22 goes on The acknowledgment becomes allowed You must set this to the es...

Page 125: ...before STO on page 132 STO active indication parameter STO output STO 21 goes on when STO is activated The FSO starts a counter for time C Note You can define an extra delay parameter SSE 16 before the FSO activates the SBC and drive STO functions not shown in the figure 3b If the drive has not ramped down fast enough when time B has elapsed the FSO activates the STO function See section Safe torq...

Page 126: ...y function is completed and the SSE completed indication parameter SSE 22 goes on The acknowledgment becomes allowed C SSE delay for STO parameter SSE 15 Time after which the FSO activates the STO function regardless of the motor speed D Response time depends on system configuration see page 532 SSE 15 Drive STO state indication SSE request Motor speed Time SSE state indication 1 6 2 5 SBC output ...

Page 127: ...BC SBC before STO on page 132 STO active indication parameter STO output STO 21 goes on when STO is activated Note You can define an extra delay parameter SSE 16 before the FSO activates the SBC and drive STO functions not shown in the figure 3b If the drive has not ramped down fast enough when time C has elapsed the FSO activates the STO function See section Safe torque off STO on page 67 for mor...

Page 128: ...stopped and the SSE completed indication parameter SSE 22 goes on The acknowledgment becomes allowed B SBC time to zero parameter SBC 13 Time from the SBC activation to the moment when the safety function is completed and the SSE completed indication parameter SSE 22 goes on The acknowledgment becomes allowed You must set this to the estimated time in which the motor brakes to a stop from the maxi...

Page 129: ...ction SSE with speed limit activated SBC SBC before STO on page 132 STO active indication parameter STO output STO 21 goes on when STO is activated The FSO starts a counter for time B Note You can define an extra delay parameter SSE 16 before the FSO activates the SBC and drive STO functions not shown in the figure 3b If the motor speed hits a ramp monitoring limit the FSO activates the STO functi...

Page 130: ...t to define the motor as stopped The safety function is completed the ramp monitoring is stopped and the SSE completed indication parameter SSE 22 goes on The acknowledgment becomes allowed C Response time depends on system configuration see page 532 Ramp monitoring limits Drive STO state indication SSE request Motor speed Time SSE state indication 1 6 2 5 SBC output 3 A C SSE completed indication...

Page 131: ...activated SBC SBC before STO on page 132 STO active indication parameter STO output STO 21 goes on when STO is activated Note You can define an extra delay parameter SSE 16 before the FSO activates the SBC and drive STO functions not shown in the figure 3b If the motor speed hits a ramp monitoring limit the FSO activates the STO function See section Safe torque off STO on page 67 for more informat...

Page 132: ...r SBC 15 Speed limit below which the FSO activates the SBC function brake B SSE delay for STO parameter SSE 15 Time after which the FSO activates the STO function regardless of the motor speed C SBC delay parameter SBC 12 Time from the activation of the SBC function to the moment when the FSO activates the drive STO function D SBC time to zero parameter SBC 13 Time from the SBC activation to the m...

Page 133: ...ive has not ramped down fast enough when time B has elapsed the FSO activates the STO function See section Safe torque off STO on page 67 for more information on how to configure the STO function 4 After time C has elapsed the FSO activates the drive STO function STO active indication parameter STO output STO 21 goes on when STO is activated 5 The SSE request is removed 6 After time D has elapsed ...

Page 134: ...cknowledgment becomes allowed C SSE delay for STO parameter SSE 15 Time after which the FSO activates the STO function regardless of the motor speed D SBC delay parameter SBC 12 Time from the activation of the SBC function to the moment when the FSO activates the drive STO function E Response time depends on system configuration see page 532 Drive STO state indication SSE request Motor speed Time ...

Page 135: ... If the drive has not ramped down fast enough when time C has elapsed the FSO activates the STO function See section Safe torque off STO on page 67 for more information on how to configure the STO function 4 After time D has elapsed the FSO activates the drive STO function STO active indication parameter STO output STO 21 goes on when STO is activated 5 The motor speed reaches the zero speed limit...

Page 136: ...Time from the activation of the SBC function to the moment when the FSO activates the drive STO function C SBC time to zero parameter SBC 13 Time from the SBC activation to the moment when the safety function is completed and the SSE completed indication parameter SSE 22 goes on The acknowledgment becomes allowed You must set this to the estimated time in which the motor brakes to a stop from the ...

Page 137: ...also the STO activation step 4 3b If the motor speed hits a ramp monitoring limit the FSO activates the STO function See section Safe torque off STO on page 67 for more information on how to configure the STO function 4 After time B has elapsed the FSO activates the drive STO function STO active indication parameter STO output STO 21 goes on when STO is activated 5 The SSE request is removed 6 Aft...

Page 138: ...pped and the SSE completed indication parameter SSE 22 goes on The acknowledgment becomes allowed C SBC delay parameter SBC 12 Time from the activation of the SBC function to the moment when the FSO activates the drive STO function D Response time depends on system configuration see page 532 Ramp monitoring limits Drive STO state indication SSE request Motor speed Time SSE state indication 1 7 2 6...

Page 139: ...ameter SSE 16 not shown in the figure before the FSO activates the SBC function This affects also the STO activation step 4 3b If the motor speed hits a ramp monitoring limit the FSO activates the STO function See section Safe torque off STO on page 67 for more information on how to configure the STO function 4 After time C has elapsed the FSO activates the drive STO function STO active indication...

Page 140: ...ate according to deceleration ramp slope defined by SLS SAR1 function The motor speed must decelerate within SAR1 minimum and maximum limits otherwise STO function is activated see section SLS with ramp monitoring and speed above monitored speed on page 145 If the SLS monitoring must be activated immediately after the SLS request regardless of the current speed time monitoring with a zero time del...

Page 141: ...ation see section SLS reaction when modulation is lost during deceleration ramp with ramp monitoring on page 147 SLS with speed below monitored speed This applies to both time and ramp monitoring A SLS trip limit positive parameter SLSx 14 SLSx 23 SLSx 33 or SLSx 43 B SLS limit positive parameter 200 23 200 33 200 43 or 200 53 SSE coast stop due to SLS trip limit hit Motor speed Time 1 3 2 4 A B S...

Page 142: ...o above the SLS limit positive 2 If the motor speed reaches the SLS trip limit positive A the FSO activates the SSE function and the motor coasts to a stop in this case the SSE function has been configured as Immediate STO parameter SSE 13 see section SLS trip limit hits on page 167 3 The SLS request is removed The SLS monitoring is still on acknowledgement method is manual or from a safety PLC pa...

Page 143: ...onfiguration see section How to configure SLSn with time monitoring on page 362 A SLS trip limit positive parameter SLSx 14 SLSx 23 SLSx 33 or SLSx 43 B SLS limit positive parameter 200 23 200 33 200 43 or 200 53 C SLS time delay parameter SLSx 04 Delay for forcing to start SLS monitoring Motor speed Time 1 5 4 3 2 6 A B C SLS request SLS monitoring SLS indication Manual acknowledgment ...

Page 144: ...s the SLS limit positive B 3 6 The drive limits the motor speed but if the motor speed still reaches the SLS trip limit positive the FSO activates the SSE function See section SLS trip limit hits on page 167 4 The FSO starts the SLS monitoring at the latest here that is after the SLS time delay C has elapsed Note If the motor speed is above the SLS trip limit after the SLS time delay C has elapsed...

Page 145: ...ction How to configure SLSn with ramp monitoring on page 364 A SLS trip limit positive parameter SLSx 14 SLSx 23 SLSx 33 or SLSx 43 B SLS limit positive parameter 200 23 200 33 200 43 or 200 53 C Response time depends on system configuration see page 532 Ramp monitoring limits SAR1 or SLS trip limit A SLS state indication C A 2 3 5 SLS request Motor speed Time SAR1 monitoring 1 B 2b 4 Safe torque ...

Page 146: ... SLS active indication parameter SLSx 15 SLSx 24 SLSx 34 or SLSx 44 goes on 2b If the motor speed does not follow the ramp monitoring limits the FSO activates the STO function See section Safe torque off STO on page 67 for more information on how to configure the STO function 3 The motor speed reaches the SLS limit positive B 3 5 The drive limits the motor speed but if the motor speed still reache...

Page 147: ...ff delay time disabled SLS reaction if modulation is lost with Modoff delay time The operation of the SLS function in case the modulation of the drive is lost during the deceleration ramp with Modoff delay time selected parameter SLSx 05 is set to Modoff delay time is described in the time diagram and table below For configuration see section How to configure SLS function behavior when drive modul...

Page 148: ... the drive parameter 23 23 defines the ramp 2 The drive trips on a fault there is a drive power loss or user stops the drive by coast stop SAR1 monitoring of the FSO is switched off SLS Modoff delay time starts parameters SLSx 05 SLSx 06 STO 14 delay starts Note This reaction is the default for FSO and the delay time is set to 0 ms 3 Modulation of the drive has not returned and the SLSx 06 Modoff ...

Page 149: ...the modulation returns before the Modoff delay time has run out with Modoff delay time selected parameter SLSx 05 is set to Modoff delay time is described in the time diagram and table below A SAR1 ramp monitoring B Actual motor speed coasting after modoff C SLS trip limit D SLS limit Motor speed Time 1 4 3 2 5 A A Drive modulation SLS request SAR1 monitoring SLSx 06 Modoff delay time monitoring S...

Page 150: ... ramp 2 The drive trips on a fault there is a drive power loss or user stops the drive by coast stop SAR1 monitoring of the FSO is switched off SLS Modoff delay time starts parameters SLSx 05 SLSx 06 STO 14 delay starts 3 Modulation of the drive returns FSO activates SAR1 monitoring again with same ramps as when the SLS request was set 4 The Modoff delay time limit If the modulation would not retu...

Page 151: ...is set to Monitoring active is described in the time diagram and table below For configuration see section How to configure SLS function behavior when drive modulation is lost on page 376 A SAR1 ramp monitoring B Actual motor speed coasting after modoff C SLS trip limit D SLS limit E Last valid speed estimate of FSO STO active Motor speed Time 1 3 4 2 A A Drive modulation SLS request SAR1 monitori...

Page 152: ...ed as Monitoring active As the modulation is lost FSO s safe speed estimation is stopped and it starts to use the last speed information that it had before the modulation was lost With SLSx 06 Monitor active SAR1 monitoring stays active also when the modulation is lost from the drive STO 14 delay starts 3 Modulation of the drive has not returned and the safe speed estimation with the last valid sp...

Page 153: ...eter SLSx 05 is set to Monitoring active and modoff delay time is described in the time diagram and table below For configuration see section How to configure SLS function behavior when drive modulation is lost on page 376 A SAR1 ramp monitoring B Actual motor speed coasting after modoff C SLS trip limit D SLS limit E Last valid speed estimate of FSO Motor speed Time 1 4 3 2 5 Drive modulation SLS...

Page 154: ... As the modulation is lost FSO s safe speed estimation is stopped and it starts to use the last speed information that it had before the modulation was lost 3 Modulation of the drive returns before the last valid speed information hits the SAR1 limit and before the modoff delay time has run out Deceleration continues as parametrized as long as the speed does not hit the SAR1 limits 4 If modulation...

Page 155: ... disabled selected parameter SLSx 05 is set to Monitoring and modoff delay time disabled is described in the time diagram and table below For configuration see section How to configure SLS function behavior when drive modulation is lost on page 376 A SAR1 ramp monitoring B Actual motor speed coasting after modoff C SLS trip limit D SLS limit SLS indication Motor speed Time 1 3 2 A A B Drive modula...

Page 156: ...starts the SAR1 ramp monitoring parameters SARx 21 SARx 22 SAR1 configuration defines the target and monitoring limits for the deceleration ramp SARx 22 200 112 SARx 02 Note If parameter 200 112 has value 0 the drive parameter 23 23 defines the ramp 2 The drive trips on a fault there is a drive power loss or user stops the drive by coast stop SAR1 monitoring of the FSO is switched off parameter SL...

Page 157: ...h Modoff delay time selected parameter SLSx 05 is set to Modoff delay time is described in the time diagram and table below For configuration see section How to configure SLS function behavior when drive modulation is lost on page 376 B Actual motor speed coasting after modoff C SLS trip limit D SLS limit SLS indication Motor speed Time 1 4 5 3 2 STO active Drive modulation SLS request SLSx 06 Mod...

Page 158: ... drive trips on a fault there is a drive power loss or user stops the drive by coast stop SLS Modoff delay time starts parameters SLSx 05 SLSx 06 STO 14 delay starts 3 Modulation of the drive has not returned the SLSx 06 Modoff delay time has run out and FSO activates STO function and STO indication parameter STO 21 STO output See section Safe torque off STO on page 67 for more information on how ...

Page 159: ...and the modulation returns before the Modoff delay time has run out with Modoff delay time selected parameter SLSx 05 is set to Modoff delay time is described in the time diagram and table below B Actual motor speed coasting after modoff C SLS trip limit D SLS limit Motor speed Time 1 6 5 4 3 2 B Drive modulation SLS request SLS monitoring SLS indication SLSx 06 Modoff time delay monitoring SLSx 0...

Page 160: ...lay time starts parameters SLSx 05 SLSx 06 3 Modulation of the drive returns before the SLSx 06 Modoff delay time has run out 4 Modoff delay time limit If the modulation would not return before this time see previous case 5 Speed is below the monitoring limit and SLS monitoring is started 6 The FSO starts the SLS monitoring at the latest here that is after the SLS time delay has elapsed The FSO st...

Page 161: ...Sx 05 is set to Monitoring active is described in the time diagram and table below For configuration see section How to configure SLS function behavior when drive modulation is lost on page 376 B Actual motor speed coasting after modoff C SLS trip limit D SLS limit E Last valid speed estimate of FSO SLS indication Motor speed Time 1 3 4 2 B E STO active Drive modulation SLS request SLSx 04 time de...

Page 162: ...n of the drive has not returned and the safe speed estimation with the last valid speed information of the motor speed is above the SLS trip limit after the SLS time delay has elapsed FSO module activates the SSE function SSE function triggers STO function because the modulation is lost and it cannot activate any deceleration ramp in this case For more information see section SLS trip limit hits o...

Page 163: ...ter modoff C SLS trip limit D SLS limit Step Description 1 The SLS request is received The motor speed is above the SLS trip limit positive A The drive starts to ramp down the motor speed The drive parameter 23 13 or 23 15 defines the deceleration ramp until the speed reaches the SLS limit The FSO starts the counter for the SLS time delay C parameter SLSx 04 2 The drive trips on a fault there is a...

Page 164: ...ff delay time disabled selected parameter SLSx 05 is set to Monitoring and modoff delay time disabled is described in the time diagram and table below For configuration see section How to configure SLS function behavior when drive modulation is lost on page 376 B Actual motor speed coasting after modoff C SLS trip limit D SLS limit Motor speed Time 1 5 4 3 2 B Drive modulation SLS indication SLS r...

Page 165: ...r the SLS time delay C parameter SLSx 04 2 The drive trips on a fault there is a drive power loss or user stops the drive by coast stop SLS delay time monitoring is switched off parameter SLSx 04 as Monitoring and modoff delay time are disabled FSO starts to wait until the STO 14 delay has run out or modulation returns 3 The drive modulation returns Deceleration continues toward SLS limit speed 4 ...

Page 166: ...ured so that Modoff delay time or Monitoring active is selected the FSO will prevent the drive from restarting until the STO 14 delay time has elapsed Step Description 1 SLS request is active during FSO boot 2 FSO module is rebooted STO 14 delay time counter is started 3 STO 14 has elapsed STO acknowledgement is possible and SLS indication is activated Note STO acknowledgement is not possible unti...

Page 167: ... page 106 SSE with immediate STO with a safe speed estimate This applies when the SSE function has been configured as Immediate STO A SLS trip limit positive parameter SLSx 14 SLSx 23 SLSx 33 or SLSx 43 B SLS limit positive parameter 200 23 200 33 200 43 or 200 53 C Response time depends on system configuration see page 532 D Time to zero speed parameter STO 14 SLS trip limit A SLS indication SLS ...

Page 168: ...es the SSE function opens the drive STO circuit and the motor coasts to a stop 5 After time D has elapsed the motor has stopped and the SLS active indication goes on speed is below the SLS limit positive The SSE completed indication goes on Note If the SBC is configured in the SSE function parameter SBC 13 is used here instead of STO 14 6 The SLS request is removed The SLS monitoring is still on a...

Page 169: ...ndication parameter SLSx 15 SLSx 24 SLSx 34 or SLSx 44 goes on 2 The motor speed goes above the SLS limit positive B 3 The motor speed reaches the SLS trip limit positive A The SLS active indication goes off 4 After time C the FSO activates the SSE function opens the drive STO circuit and the motor coasts to a stop 5 The motor speed goes below the SLS limit positive B The SLS indication goes on 6 ...

Page 170: ...he FSO starts the SLS monitoring The SLS indication parameter SLSx 15 SLSx 24 SLSx 34 or SLSx 44 goes on 2 The motor speed goes above the SLS limit positive B 3 The motor speed reaches the SLS trip limit positive A The SLS active indication goes off 4 After time C has elapsed the FSO activates the SSE function and the drive starts the ramp down the motor speed SAR0 parameter 200 102 defines the ra...

Page 171: ...Safety functions 171 8 The SLS function is acknowledged and the FSO stops the SLS monitoring The SSE function is acknowledged with the same acknowledgement The indications go off Step Description ...

Page 172: ... percentage The scaling value is used to scale the original SLS and trip limits SLS4 parameters to new scaled values The FSO module uses these scaled values until a new scaling value is received from the safety PLC The Variable SLS limits cannot be scaled above the SLS4 limits In the PROFIsafe message the bits that are used to configure the Variable SLS function are Positive_Scaling defines whethe...

Page 173: ...he FSO sends a request to the drive to ramp down the motor speed to the new SLS speed limit The FSO start a counter for the SLS time delay B 2 After time C has elapsed the drive starts to ramp down the motor speed The drive parameter 23 13 or 23 15 defines the deceleration ramp The FSO starts the SLS monitoring when the motor speed is in the middle of the new SLS limit and the SLS trip limit see a...

Page 174: ...nfigure limit hit situations on page 394 The FSO starts the SLS monitoring when the motor speed is in the middle of the new SLS limit and the SLS trip limit see also section How to configure mute time for monitoring start on page 399 7 The new motor speed has been reached The SLS active indication goes on 8 The FSO starts the SLS monitoring with the new SLS limits at the latest here that is after ...

Page 175: ... Variable SLS request is received from the safety PLC for example 70 The FSO sends a request to the drive to ramp down the motor speed to the new speed limit 2 3 After time B has elapsed the drive starts to ramp down the motor speed SAR1 parameter 200 112 defines the deceleration ramp The FSO starts to monitor the ramp according to SAR1 parameters SARx 21 SARx 22 Note If parameter 200 112 has valu...

Page 176: ...d the FSO starts to monitor the motor speed according to the new SLS limits The Variable SLS active indication goes on 7 The Variable SLS request is received again from the safety PLC 100 The FSO sends a request to the drive The FSO starts to monitor the motor speed according to the new SLS limits 8 After time B has elapsed and if the motor speed is lower than the new speed limit the drive acceler...

Page 177: ...f the motor speed reaches the minimum or the maximum SMS trip limit the FSO module activates the SSE function 2 Version 2 The minimum and maximum SMS limits limit the motor speed This version of the SMS function is similar to the SLS function except that it can only be permanently on or off The required version of the SMS function is selected with FSO parameters You can configure the minimum and m...

Page 178: ...function In this case the SSE function has been configured as Immediate STO parameter SSE 13 This opens the drive STO circuit immediately and the motor coasts to a stop The STO and SSE indications go on Note If SBC is used it is activated according to SBC configuration settings see the note on page 49 See section Safe stop emergency SSE on page 106 for more information on how to configure the SSE ...

Page 179: ... on how to configure the SSE function If you use the SMS function version 2 and you need to remove the FSO module from the drive do these steps 1 Re configure the FSO module so that the SMS function version 2 is deactivated set parameter 200 71 SMS activity and version to Disabled For more information see chapter Configuration 2 Remove the FSO module from the drive This removes the SMS limits from...

Page 180: ...s see the corresponding drive hardware manual The operation of the POUS function is described in the time diagram and table below For configuration see section Configuring POUS on page 376 A POUS delay for completion parameter POUS 13 Sets a delay for POUS completed indication The POUS completed indication parameter POUS 22 goes on after this delay Note POUS function does not activate SBC function...

Page 181: ...tion becomes active parameter POUS 22 Note Connect the POUS indication lamp to this indication signal 4 The user removes the POUS request The POUS completed indication is deactivated The acknowledgement becomes allowed Note If the user activates the POUS request again before the POUS function has been acknowledged the counter for time A is restarted and the POUS completed indication is activated a...

Page 182: ...he FSO module is always aware of the exact motor speed Without an encoder the speed information is valid only when the drive is modulating see section SSM with a safe speed estimate on page 184 Note If there is a fault in the speed data and the SSM function is the only active safety function this does not trip the drive This only removes the SSM indication and generates a warning to the drive The ...

Page 183: ...es on 2 The motor speed goes above the SSM1 limit positive A the SSM1 indication goes off 3 The motor speed goes below the SSM1 limit positive A the SSM1 indication goes on 4 The motor speed goes below the SSM1 limit negative B the SSM1 indication goes off 5 The motor speed goes above the SSM1 limit negative B the SSM1 indication goes on 6 The SSM1 request is removed and the FSO stops the SSM1 mon...

Page 184: ...limit positive B The SSM1 indication goes on 2 The drive stops modulating and the FSO starts a counter for time C The motor speed starts to decelerate While the drive is not modulating the state of the FSO outputs is based on the latest speed information from modulation 3a The drive starts to modulate again and the FSO receives the actual motor speed again The motor speed is between the SSM1 limit...

Page 185: ...ation is off 2 The drive stops modulating and the FSO starts a counter for time C The motor speed starts to decelerate While the drive is not modulating the state of the FSO outputs is based on the latest speed information from modulation 3a The drive starts to modulate again and the FSO receives the actual motor speed again The motor speed is between the SSM1 limit positive A and SSM1 limit posit...

Page 186: ...he SSE function and the motor stops If the motor does not rotate in the correct direction when the SDI function is activated the motor speed is first decelerated to zero speed You can configure the SDI function to use either the time monitoring or ramp monitoring method when the motor speed is decelerated After the user has given a new speed reference the motor starts to rotate to the correct dire...

Page 187: ... motor starts to rotate again into the positive direction 4 The rotation direction of the motor changes to the forbidden negative direction The FSO locks the SDI tolerance limit degree A into its current position 5 The motor stops before the SDI tolerance limit A is reached 6 The motor starts to rotate again into the positive direction 7 The motor continues to rotate to the correct direction and t...

Page 188: ... example A SDI delay parameter SDI 12 Delay for forcing to start the SDI monitoring B Zero speed with encoder parameter FSOGEN 52 Speed limit to define the motor as stopped The safety function is completed and the SSE completed indication parameter SSE 22 goes on The STO acknowledgment becomes allowed SDI state indication SDI request Motor speed Time B 1 2 4 A 2b SDI 12 SSE state indication 2b 3b ...

Page 189: ...e SDI delay A has elapsed Note If the rotation direction of the motor is not correct after the SDI delay A has elapsed the FSO module activates the SDI monitoring If the motor rotates to the forbidden direction more that the SDI tolerance limit degree parameter SDI 14 not shown in this figure allows the FSO activates the SSE function and the motor coasts to a stop in this case the SSE function has...

Page 190: ...nction is used as an example A Zero speed with encoder parameter FSOGEN 52 Speed limit to define the motor as stopped The safety function is completed and the STO completed indication parameter STO 22 goes on The STO acknowledgment becomes allowed Ramp monitoring limits SDI state indication SDI request Motor speed Time A 1 2 4 2b 3b SAR1 monitoring STO state indication 2b 3 Safe torque off STO ...

Page 191: ...not shown in this figure see section SDI with correct rotation direction on page 186 The SDI active indication goes on 2b If the deceleration of the motor does not follow the ramp monitoring limits the FSO module activates the STO function and the motor coasts to a stop The STO indication goes on parameter STO 21 See section Safe torque off STO on page 67 for more information on how to configure t...

Page 192: ...e motor starts to rotate again into the positive direction 4 The rotation direction of the motor changes to the forbidden negative direction The FSO locks the SDI tolerance limit A into its current position 5 The SDI tolerance limit A is reached The FSO stops the SDI monitoring and activates the SSE function and the motor coasts to a stop The SDI indication goes off The SSE indication goes on See ...

Page 193: ...e SS1 function Therefore SAR0 parameters are used instead of SAR1 parameters to define the stop ramp When a safety function overrides another safety function this does not remove the request of the overridden safety function Therefore the overridden safety function restarts after the other safety function has been completed and acknowledged Dependencies between safety functions The figure below sh...

Page 194: ...SLS1 4 Variable SLS POUS FSO STO Drive STO Time monitoring Ramp monitoring with SAR0 ramp Immediate STO Emergency ramp 3 Monitoring limit hit Zero speed limit reached 1 Trip limit hit 2 3 1 SDI 2 Time monitoring Ramp monitoring with SAR1 ramp Ramp monitoring with SAR1 ramp 3 Time monitoring ...

Page 195: ...tion must be secured This can be done with the PROFIsafe technology The PROFIsafe technology includes several safety measures to minimize the effect of various transmission errors that can occur when messages are transferred in a complex network PROFIsafe is an application layer protocol that describes the safety communication between fail safe devices It is an additional layer on top of the stand...

Page 196: ... 12 or later DCS880 Firmware version 2 07 or later FB module FPNO 21 PROFINET fieldbus adapter module version 1 00 or later or FENA 21 Ethernet adapter module version 3 05 or later compatible safety PLC system for example ABB AC500 S Safety PLC or Siemens SIMATIC Fail safe S7 PLC Tools Drive composer pro version 1 7 or later For ABB PLCs Automation builder 1 0 or later includes PS501 Control Build...

Page 197: ...re it is processed and vice versa The safety PLC sends PROFIsafe messages frames to the FSO module through the FB module which extracts the frame from the PROFINET communication The FSO module reads and interprets the PROFIsafe messages and performs the required actions The FSO module sends PROFIsafe messages back to the FB module which transmits them to the safety PLC The term PROFIsafe F Output ...

Page 198: ...t all PROFIsafe devices support F Parameters are sent from the F Host safety PLC to the F Device FSO module when the PROFIsafe connection is created They contain the PROFIsafe addresses and the watchdog time for the PROFIsafe connection Note ABB recommends that you use only PROFINET compatible Ethernet switches and cables in the PROFIsafe communication bus ...

Page 199: ...dule modes and states on page 212 To exit the Fail safe mode reboot the FSO as described in Internal fault on page 505 FSO module passivation If the FSO module or the safety PLC detects an error in the fieldbus communication the FSO module is passivated The status of the FSO outputs that are not configured for any control use for example to control an indication lamp or a brake are set to low The ...

Page 200: ...ontrol Byte and CRC2 No is the length of F Output user data Data F Input F Output user data Status Control Byte CRC2 Size octets Max 12 1 3 Octet Bit Name Description Control Byte No 7 Reserved The value is ignored 6 Reserved The value is ignored 5 Toggle_h Toggle bit 4 Activate_FV Fail safe values FV to be activated 3 Use_TO2 Use F_WD_Time_2 secondary watchdog Not in use The value is ignored 2 R_...

Page 201: ...e FSO I O In addition to the functionality in the ABB_PS1 profile the ABB_PS2 profile includes the safe position data The ABB_PS2 profile requires that an encoder is used in the safety system Octet Bit Name Description Status Byte Ni 7 Reserved The value is always 0 Must be ignored by the F Host 6 cons_nr_R Vconsnr_d has been reset 5 Toggle_d Toggle bit 4 FV_activated Fail safe values FV activated...

Page 202: ...e stop 1 activation requested by the controller 5 SSE_request SSE Safe stop emergency activation requested by the controller 6 POUS_request POUS Prevention of unexpected start up activation request by the controller 7 STO_request STO Safe torque off activation requested by the controller Unsig ned16 used as bits 1 0 SDI_N_ activate SDI_N Safe direction activation requested by the controller 1 SDI_...

Page 203: ...rl State of the safe output X114 7 see section Remote I O control on page 199 1 24 V 0 0 V 3 Safe_output_X113 _9_ctrl State of the safe output X113 9 see section Remote I O control on page 199 1 24 V 0 0 V 4 Safe_output_X113 _8_ctrl State of the safe output X113 8 see section Remote I O control on page 199 1 24 V 0 0 V 5 Safe_output_x113 _7_ctrl State of the safe output X113 7 see section Remote I...

Page 204: ...ve and the motor speed is below the SLS1 limit that is when the SLS1 monitoring is on 2 Reserved The value is 0 Must be ignored by the F Host 3 Reserved The value is 0 Must be ignored by the F Host 4 SS1_active SS1 Safe stop 1 is function active 5 SSE_active SSE Safe stop emergency function is active 6 SBC_active SBC Safe brake control function is active 7 STO_active STO Safe torque off function i...

Page 205: ...ts 3 0 Safe_input_X114_4 State of the safe input X114 4 1 Safe_input_X114_3 State of the safe input X114 3 2 Safe_input_X114_2 State of the safe input X114 2 3 Safe_input_X114_1 State of the safe input X114 1 4 Safe_input_X113_4 State of the safe input X113 4 5 Safe_input_X113_3 State of the safe input X113 3 6 Safe_input_X113_2 State of the safe input X113 2 7 Safe_input_X113_1 State of the safe ...

Page 206: ... about safety function states there are other ways to safely determine the state of a function for example using SS1 to check octet 0 bit 4 and then octet 5 bit 4 if safe state then SS1 is completed 2 STO_control_active The drive STO circuit is open Note The motor may still be rotating 3 Speed_value_valid Is the speed value valid 1 or not 0 The speed value is defined in octets 6 and 7 Note Octet 2...

Page 207: ...activation requested by the controller 1 SLS1_request SLS1 Safely limited speed activation requested by the controller 2 Reserved Must not be used must be 0 3 Reserved Must not be used must be 0 4 SS1_request SS1 Safe stop 1 activation requested by the controller 5 SSE_request SSE Safe stop emergency activation requested by the controller 6 POUS_request POUS Prevention of unexpected start up activ...

Page 208: ... State of the safe output X114 7 see section Remote I O control on page 199 1 24 V 0 0 V 3 Safe_output_X113 _9_ctrl State of the safe output X113 9 see section Remote I O control on page 199 1 24 V 0 0 V 4 Safe_output_X113 _8_ctrl State of the safe output X113 8 see section Remote I O control on page 199 1 24 V 0 0 V 5 Safe_output_x113 _7_ctrl State of the safe output X113 7 see section Remote I O...

Page 209: ...ve and the motor speed is below the SLS1 limit that is when the SLS1 monitoring is on 2 Reserved The value is 0 Must be ignored by the F Host 3 Reserved The value is 0 Must be ignored by the F Host 4 SS1_active SS1 Safe stop 1 function is active 5 SSE_active SSE Safe stop emergency function is active 6 SBC_active SBC Safe brake control function is active 7 STO_active STO Safe torque off function i...

Page 210: ...ts 3 0 Safe_input_X114_4 State of the safe input X114 4 1 Safe_input_X114_3 State of the safe input X114 3 2 Safe_input_X114_2 State of the safe input X114 2 3 Safe_input_X114_1 State of the safe input X114 1 4 Safe_input_X113_4 State of the safe input X113 4 5 Safe_input_X113_3 State of the safe input X113 3 6 Safe_input_X113_2 State of the safe input X113 2 7 Safe_input_X113_1 State of the safe ...

Page 211: ...er ways to safely determine the state of a function for example using SS1 to check octet 0 bit 4 and then octet 5 bit 4 if safe state then SS1 is completed 2 STO_control_active The drive STO circuit is open The motor may still be running 3 Speed_Pos_value_v alid Are the speed and position values valid 1 or not 0 The speed value is defined in octets 6 and 7 The position value is defined in octets 8...

Page 212: ...uring normal operation The second figure shows the modes states and transitions when fatal errors in the FSO module occur or when cycling power of the FSO module Note If PROFIsafe is not configured see the FSO states described in section FSO states on page 60 in chapter Safety functions Note If PROFIsafe is configured the FSO module stays in the Start up mode until it has received valid F Paramete...

Page 213: ...he drive is not modulating From the Configuration mode it is possible to go only to the Start up mode Start up Fail safe Safe Module passivation Safe User acknowledgement request Safe Module passivation with a command Safe Module passivation reintegration Operational RUN 22 1 3 20 21 10 23 30 18 7 8 27 11 31 29 28 19 Configuration 24 Power down Drive composer pro 32 Internal fault 33 ...

Page 214: ...le occur or when cycling power of the FSO module Start up Fail safe Safe Module passivation Safe User acknowledgement request Power on off Fatal error Safe Module passivation with a command Safe Module passivation reintegration Operational 16 13 9 5 12 25 6 15 17 14 26 4 2 9 2 RUN Configuration 32 33 ...

Page 215: ... been solved The FSO is in the Safe User acknowledgement request state and variable OA_Req_S is set to 1 Setting OA_C variable to 1 acknowledges that the PROFIsafe communication errors have been solved and it is possible to go to the Operational state Device_Fault This variable is the Device_Fault bit of the PROFIsafe Status Byte When the value is 1 the FSO is in the Fail safe mode State Descripti...

Page 216: ...nning without any detected errors PROFIsafe Status Byte bits in the F Host for the FSO module OA_Req_S 0 FV_activated_S 0 Device_Fault 0 ABB_PS1 or ABB_PS2 profile bits in the F Host for the FSO module FSO_mode 1 0 FSO_mode 0 1 SF_end_ack_req_local 0 SF_end_ack_req 0 FSO_state 0 State Description ...

Page 217: ...O inputs SF_end_ack_req is set if any of the safety functions can be acknowledged via PROFIsafe frame bit SF_end_ack A positive edge from 0 to 1 is required to acknowledge the module reintegration If automatic acknowledgement is configured for the error condition neither of the status bits is set The acknowledgement is done automatically As soon as all errors have been solved and they have been ac...

Page 218: ...ail safe value 0 is transferred to the safety PLC for all I O channels If the PROFIsafe communication is broken the safety application continuously attempts to establish a communication to the safety PLC A state transition to another RUN state is possible only if the detected error has been solved PROFIsafe Status Byte bits in the F Host for the FSO module if communication is possible OA_Req_S 0 F...

Page 219: ...ode 1 0 FSO_mode 0 1 SF_end_ack_req_local 0 SF_end_ack_req 0 FSO_state 1 Safe User acknowledgement request PROFIsafe communication is up and running The FSO application is running without any errors but waits for the acknowledgment of a module reintegration module error has been solved The FSO module is in the Safe state The fail safe value 0 is still transferred to the safety PLC for all input ch...

Page 220: ...e FSO_mode 1 1 FSO_mode 0 0 SF_end_ack_req_local 0 SF_end_ack_req 0 FSO_state 1 See also the Note on page 204 Configuration The FSO module is in the Safe state Upon transferring to the Configuration mode the FSO answers to one PROFIsafe frame The fail safe value 0 is transferred to the safety PLC for all I O channels After that PROFIsafe communication is not possible The fail safe value 0 is set t...

Page 221: ...rive parameter 96 09 FSO reboot see the drive firmware manual 5 Start up Fail safe Fatal error s CPU test RAM test etc failed detected 6 Fail safe Start up The FSO module goes to the Start up mode by cycling power of the FSO module or by giving the reset command via the drive parameter 96 09 FSO reboot see the drive firmware manual 7 Operational Safe Module passivation reintegration Execution of a...

Page 222: ...O module or by giving the reset command via the drive parameter 96 09 FSO reboot see the drive firmware manual 18 Safe Module passivation with a command Safe Module passivation PROFIsafe watchdog time or PROFIsafe communication error was detected 19 Safe Module passivation Safe Module passivation with a command Module error watchdog time or communication error CRC has been solved and command activ...

Page 223: ... a command Command activate_FV_C 1 was sent from the safety PLC 30 Safe User acknowledgement request Safe Module passivation reintegration OA_C positive edge was set by the PROFIsafe F Host but there are existing errors in the active safety functions or there are errors that need to be acknowledged 31 Safe Module passivation with a command Safe Module passivation reintegration Command activate_FV_...

Page 224: ...me difference between the watchdog time for a given entity and the worst case delay time In safety systems to define SFRT you must take into account a potential single fault in one of the components during the signal transfer It is enough to consider a single fault only see PROFIsafe System Description Version November 2010 The worst case delay time WCDT and watchdog WD values for the FSO and FENA...

Page 225: ... values the calculation uses watchdog times See AC500 S Safety User Manual 3ADR025091M0207 English for details For example when using the ABB AI581 S as the input device the SM560 S safety PLC and the FSO module as the output device SFRT can be calculated as follows SFRT Device_WD1 0 5 x F_WD_Time1 F_Host_WD 0 5 x F_WD_Time2 Device_WD2 Longest T_WD 76 5 15 6 45 5 50 45 5 238 5 ms where Device_WD1 ...

Page 226: ...e PROFIsafe frame is transmitted from the F Device FSO module to the F Host such as the ABB SM560 S safety controller station through the black channel 3 Host acknowledgement time HAT is the time it takes for the F Host to process an incoming PROFIsafe frame 4 Another Bus time elapses when the new PROFIsafe frame is transmitted from the F Host back to the F Device F_WD_Time assigned to the FSO mod...

Page 227: ...device If you use this approach for the FSO module you can set the PROFIsafe cycle time and the corresponding watchdog time F_WD_Time as short as possible for the given system If the longest recorded PROFIsafe cycle time minimum F_WD_Time is for example 40 ms a suitable value for F_WD_Time is F_WD_Time 40 ms x 1 3 52 ms If you can calculate F_WD_Time instead use the values given in the table on pa...

Page 228: ...he drive hardware manual 2 Install the FB module to the drive See the appropriate manual FENA 01 11 21 Ethernet adapter module user s manual 3AUA0000093568 English or FPNO 21 PROFINET adapter module user s manual 3AXD50000158614 English 3 Connect the FB module to the safety PLC through a PROFINET network See the manual of the module and the manual of the safety PLC ...

Page 229: ...0 31 FBA B enable 2 Set the FB module parameters that correspond to the selected fieldbus channel Parameter groups 51 52 and 53 include the settings for FBAA and groups 54 55 and 56 for FBA B Groups 52 53 55 and 56 configure the contents of the normal PROFINET cyclic communication by mapping the words in the PROFINET frame to the desired drive parameters Groups 51 and 54 configure the PROFINET con...

Page 230: ... 318 51 54 02 FBA A B PAR2 PROTOCOL PROFILE Selects one of the PNIO profiles 11 PNIO ABB Pro Profile PNIO ABB Pro is selected 51 54 03 FBA A B PAR2 COMMRATE Sets the Ethernet communication rate 0 Auto Ethernet communication rate is negotiated automatically by the device 51 54 04 13 IP CONFIGURATI ON The user can set the IP configuration for the network in these parameters or in the PLC project Sta...

Page 231: ...ific features for example in the ABB Drives communication profile The PROFIdrive profile supports a set of services described in the PROFIdrive specification The actual PROFIsafe messages are processed in the FSO module The GSD file and the instructions in this chapter refer to the FB module which is the device that is connected to PROFINET Configuring the ABB AC500 S Safety PLC This example shows...

Page 232: ...BB Document library See section Downloading the GSD file on page 231 1 Start the ABB Automation Builder application 2 On the Tools menu select Device Repository 3 In the window that opens click Install and browse for the GSD file 4 Open or create the PLC project that is used to control the drive ...

Page 233: ...ntroller devices to the PLC project Next add the necessary controller devices to the PLC project First add the safety controller to slot 1 make sure that the physical controller is in the same slot Right click on the slot select Add object and pick the SM560 S safety controller from the list ...

Page 234: ...PROFIsafe Note When adding the safety controller a login screen will appear The default login information is User name Owner Password empty Next in the same way add the CM579 PNIO PROFINET master to slot 2 ...

Page 235: ... the safety controller station if you want to view or debug the PLC program after the download 6 Right click on the PROFINET controller CM579 PNIO Master and add the FENA module to the PROFINET IO network Controller station Safety controller station PROFINET controller ...

Page 236: ...236 PROFIsafe ...

Page 237: ... the first slot of the FENA module to define cyclic communication between the module and the PLC 8 Add the PROFIsafe module PROFIsafe ABB_PS1 to the second slot of the FENA module to define cyclic communication between the module and the PLC I O module PROFIsafe module ...

Page 238: ...On the PNIO identification tab define the IP address and Subnet mask and type the Station name in this example drive1 Note Use only lower case letters for the Station name 11 Set the communication parameters if you have already done this you can move on to the next step Create configuration data for safety and non safety Right click on the PLC_AC500_V2 controller and open the communication setting...

Page 239: ...PROFIsafe 239 In the advanced settings create a new local profile with the following parameters Next open the CoDeSys safety program and choose Communication ...

Page 240: ...240 PROFIsafe parameters from the Online drop down menu Now create a new profile and fill in the following parameters Next check that your network adapter is in the same subnet Open the ...

Page 241: ...241 Windows network and sharing center and click on the network adapter Navigate to the IPv4 properties Finally set your subnet to the same range as the PLC Check that the IP address is not in use on the network ...

Page 242: ...iguration data for safety and non safety Note The PROFIsafe source and destination addresses have to be different in order for the configuration process to work Also when creating safety data some libraries will have to be created ...

Page 243: ...ign I O Device name In the IP address and Network mask boxes type the IP address and subnet mask defined in step 11 and click Assign IP configuration 14 Define the I O module properties Select the I O module PPO_Type_4 On the General tab configure the Stop Mode Action and Control zero mode functions and define Fail safe values for the PLC output process data PZDs Rename the I O modules for example...

Page 244: ... PROFIsafe safety parameters Three of the listed parameters can be modified for FENA F_Source_Add is the address of the safety controller station in this example AC500 SM560 S F_Dest_Add is the address of the FENA module This is defined by FSO parameter PROFIsafe 11 see section Configuring the safety fieldbus communication on page 318 ...

Page 245: ...guration data for the controller station Right click on the AC500_S and select Create Safety Configuration Data 18 Download the safety and non safety PLC programs This is done through Codesys by double clicking on Application Then in Codesys open Online drop down menu and choose Login Same is done to the safety program by double clicking on AC500_S Note The non safety program may be empty but the ...

Page 246: ... Do not use this safety program in real safety applications This safety program is shown only as an example and can only be used for trial purposes Note This example program also keeps the SLS3 function active all the time ...

Page 247: ...changes have been made select Clean all from the Project menu In the window that opens click Yes This downloads the program to the PLC In the Online menu select Create boot project This saves the program permanently to the PLC In the Online menu select Logout 22 Repeat step 21 for the safety program 23 Switch the power of both PLCs off and on 24 For the non safety program In the Online menu select...

Page 248: ...OFIsafe Monitoring the PROFIsafe message It is possible to monitor the contents of the PROFIsafe message For example 1 Check the variable values in the Current Value column on the PNIO Module I O Mapping tab ...

Page 249: ...s see the documentation of the safety PLC S7 Distributed Safety configuring and programming Programming and Operating Manual 07 2013 A5E00109537 05 Before you start make sure that you have downloaded the FENA GSD file from the ABB Document library See section Downloading the GSD file on page 231 1 Start SIMATIC Manager and open create a SIMATIC project 2 Add the necessary objects to the project In...

Page 250: ...ontroller station V2 8 that is installed in a RACK 300 Rail 5 When you install the controller station to the rail select Industrial Ethernet as the subnet for the controller station 6 Install the FENA GSD file In the Options menu select Install GSD Files Browse for the GSD file that you downloaded from the ABB Document library Click Install ...

Page 251: ...f the SIMATIC environment you have to close the whole SIMATIC program and open it again to make the new GSD file visible in the object catalogue 7 Click and drag the FENA object from the device catalog to the Ethernet 1 PROFINET IO System ...

Page 252: ...the FENA module to define cyclic standard communication between the module and the PLC 9 Click and drag the PROFIsafe object PROFIsafe ABB_PS1 to the second slot of the FENA module to define cyclic safety communication between the module and the PLC 10 Double click FENA to open the Properties window ...

Page 253: ...apter module also in other tools eg the Drive composer pro PC tool which you use to connect to the drive 12 Click OK 13 In the hardware configuration double click the I O object PPO Type 4 in Slot 1 to open the Properties window This is the IP address that will be assigned to the FENA adapter module To modify the IP address click the Ethernet button The IO controller assigns the IP address ...

Page 254: ... 14 Type a name for the I O object in this example PROFIsafe ABB_PS1 15 On the Parameters tab configure the Stop mode and Control zero mode functions and define Fail safe values for the PLC output process data PZDs ...

Page 255: ... hardware configuration click FENA In the PLC menu select Ethernet and select Assign Device Name Click the Update button Click the available device with the correct MAC address to which the device name will be assigned Click Assign name This assigns the name to the FENA module Click Close ...

Page 256: ...e hardware configuration double click the controller station for example CPU 319F 3 Select the F Parameters tab When prompted give the password for the Safety Program See the documentation of the SIMATIC system for details Make the necessary changes and click OK ...

Page 257: ...n modify this in the host F Parameters tab F_Dest_Add is the address of the FENA module This is defined by FSO parameter PROFIsafe 11 see section Configuring the safety fieldbus communication on page 318 These two define the codename for the PROFIsafe relationship of this particular FENA module and the safety controller station F_WD_Time is the PROFIsafe watchdog time See section Calculating the w...

Page 258: ...peat the same for the PROFIsafe object PROFIsafe ABB_PS1 in Slot 2 Note In PROFINET communication the bits of each octet are sent the most significant bit first Therefore the bits of every octet in the PROFINET message are in reversed order compared to the bits shown in the figure For example the first bit that is sent in the PROFINET message is the 7th bit of the first octet I 0 7 ...

Page 259: ...on for example CPU 319F 3 Select Protection tab Select 1 Access protect for F CPU Check Can be bypassed with password Enter the password twice to the edit boxes Check CPU contains safety program 21 Save compile and download the hardware configuration to the PLC The PLC is now ready for communication with the FENA adapter module ...

Page 260: ...ations This safety program is only an example which you can use only for trial purposes to get the system up and running 1 In SIMATIC Manager right click on the Blocks folder of the S7 Program of the project 2 Select Insert New Object and add the following blocks to the program Organization Block OB35 to call the safety program cyclically Function Block FB1 using F FBD language Function FC1 using ...

Page 261: ...ose the dialog windows 6 In SIMATIC manager double click on OB35 7 Add call to FC1 by dragging the FC1 block from the FC blocks folder 8 Save the block and close the editor 9 In SIMATIC manager double click on FB1 10 Add acknowledgement for reintegration by assigning the value of ACK_REQ to ACK_REI in DB2185 ...

Page 262: ...ample program also keeps the SLS3 function active all the time 12 In SIMATIC Manager select Edit safety program from the Options menu 13 Select Compile 14 Select Download If prompted accept the inclusion of standard blocks 15 Switch the controller station to run mode ...

Page 263: ...263 Monitoring the PROFIsafe message It is possible to monitor the contents of the PROFIsafe message For example 1 In HW Configuration select Monitor Modify for the PROFIsafe telegram in Slot 2 of the FENA module ...

Page 264: ...264 PROFIsafe Configuring Siemens S7 1200 PLC with TIA14 This example can be done with FENA 21 or FPNO 21 adapter modules 1 Open TIA14 and create a new project ...

Page 265: ...PROFIsafe 265 2 Select your CPU from the list 3 Install the FENA 21 GSDML file ...

Page 266: ...device configuration by dragging it from the hardware catalog 5 Open the FENA 21 device view and add by dragging and dropping the desired PPO and PS telegrams to slot 1 and 2 In this example we use PPO7 and PS2 Additional info in manuals ...

Page 267: ...PROFIsafe 267 6 Network view shows E stop icon on the FENA device to indicate that device has safety I O 7 Assign FENA 21 to PROFINET controller Network configuration is updated ...

Page 268: ...ge below 8 Select PLC from network view and Properties will show on the bottom of the screen In PLC properties enable F capability safety and PROFIsafe under the Fail safe submenu 9 In the F parameters submenu define the maximum allowed safety program execution interval If this value is exceeded PROFIsafe goes to safe state watchdog ...

Page 269: ... the PLC IP address 11 In Advanced options set PLC minimum cycle time for I O and PROFINET communication PROFINET cycle time 12 For testing purposes you can disable the PLC password Remember to enable the PLC password after you have done the validation ...

Page 270: ... the FENA 21 IP address and PROFINET device name The device name will be used as identification After successful identification PLC will assign IP address to FENA Note FB module parameters 51 04 onwards should be static 0 0 0 0 in the drive ...

Page 271: ...Isafe 271 14 Configure FENA ABB PS PROFIsafe settings F_Source_Add PLC PROFIsafe address F_Dest_Add FSO PROFIsafe address F_WD_Time Maximum allowed PROFIsafe message cycle time In this example we use 200 ms ...

Page 272: ...272 PROFIsafe 15 Add OB86 Rack or station failure program block to prevent PLC from stopping on I O error 16 Add new Function block ABB_Drive ...

Page 273: ...PROFIsafe 273 17 Add variables to ABB_Drive FB 18 Add ABB_Drive FB to OB1 Assign new instance Data Block for ABB_Drive FB When using multiple drives create one DB for each drive ...

Page 274: ...274 PROFIsafe 19 Select the corresponding FENA PPO address for the drive HW input The value can be verified from the HW configuration in the FENA PPO type properties under the Hardware Identifier tab ...

Page 275: ...PROFIsafe 275 20 In ABB_Drive FB add blocks DPRD_DAT and DPWR_DAT 21 Insert values to blocks ...

Page 276: ...Later the PPO message data can be found in ABB_Drive1_DB 22 In PLC Safety Administration configure F runtime group cycle time warn and maximum cycle time limits If maximum limit is exceeded PLC will go to safe state ...

Page 277: ...OFIsafe 277 23 Create tag table for ABB_PS2 safety functions See bit descriptions from FSO PROFIsafe profiles Chapter 6 See correct I O addresses from HW configuration 24 Save and download project to PLC ...

Page 278: ...278 PROFIsafe 25 Scan for accessible devices start search Note that a firewall can block traffic 26 In device configuration right click FENA icon and select Assign device name ...

Page 279: ...ntify the correct FENA based on MAC ID label Click Assign name Note The MAC ID can be found on the cover of the FB module The PLC will assign a name and IP address to the selected FENA and drive parameter group 51 values will update accordingly ...

Page 280: ...In this case make sure that drive parameter 51 21 is set to Enabled see the drive firmware manual ABB AC500 S In the ABB AC500 S system you can read PROFINET diagnostics messages from Control Builder Plus or with a separate PNIO_DEV_DIAG function block in the non safety PLC program To read the alarm data of the last active alarm from Control Builder Plus 1 Select FENA_21 2 On the Diagnostics for P...

Page 281: ...ATIC Manager To read diagnostics messages 1 In the PLC menu select Diagnostic Setting 2 Select Hardware diagnostics 3 In the window that opens select the FENA module of your system 4 Click the Module Information button ...

Page 282: ...282 PROFIsafe 5 To read the diagnostic messages select the I O Device Diagnostics tab ...

Page 283: ...ule Value hex Description Notes 64 0x0040 Mismatch of safety destination address F_Dest_Add F_Dest_Add did not match the value configured in the safety parameters PROFIsafe 11 PROFIsafe F_Dest_Add 65 0x0041 Safety destination address is not valid F_Dest_Add F_Dest_Add of 0 or FFFFh is not allowed A valid F_Dest_Add is within range 1 65534 66 0x0042 Safety source address is not valid F_Source_Add F...

Page 284: ... calculated over the F Parameters does not match the checksum value in the F Parameters 72 0x0048 Device specific diagnosis information Unsupported PROFINET submodule identification number received from the controller station upon PROFINET connection or general error in the F Parameters Fault Cause What to do You cannot start the PROFINET communication The FB module station name saved in the FB mo...

Page 285: ...exceeds often The watchdog time is too short Calculate a new watchdog time See section Calculating the watchdog time on page 227 All errors solved but you still cannot start the PROFIsafe communication After you have modified the configuration of the safety devices you may have to reboot the whole system before the changes take effect Reboot the safety PLC If this does not help reboot also the FSO...

Page 286: ...286 PROFIsafe ...

Page 287: ...ommon Cause Failures CCF See the checklist for the appropriate standard in section Checklists on page 305 Mechanical installation Installation site The subsystem elements must always be likely to operate within the range of temperature humidity corrosion dust vibration etc for which they are specified without the use of external environmental control see section Ambient conditions on page 518 The ...

Page 288: ...nd clamped where practicable When installing cabling it must be assured that there is no pulling or pinching on the cables Connections Inputs and outputs To design the safety system architecture and select components to be used it is essential to read and understand the different architecture options for example single channel redundancy Single inputs can be connected to any terminal X113 1 4 or X...

Page 289: ...a reverse polarity protection FSO module enters Fail safe mode if any of these protections trip The module enters Fail safe mode also if output voltages of the internal power supply are outside specified limits due to supply input over voltage Note If you de energize the FSO module you cannot operate the drive Power supply for the FSE module and safety encoders You have to use the same power suppl...

Page 290: ...signaling take care to avoid common cause failures in the cables This can be done by routing the two channels through two well apart routes or by protecting the cabling appropriately for example by using double shielded cables Never mix 24V level signals with non ELV signals or power feeds in the same cable Safety Related Electronic Control System SRECS signal cables for the individual channels mu...

Page 291: ...utton Relay contactor output with feedback Examples Brake control Door gate unlock 1 10 9 8 7 6 5 4 3 2 X114 TP DO GND DI X113 Physical separation of the different channels or appropriate cable protection eg double shielding Channel separation Diagnostic pulses 1 10 9 8 7 6 5 4 3 2 X114 TP DO GND DI X113 Diagnostic pulses ...

Page 292: ...and redundant 2 channel solutions The safe brake control needs a feedback from the brake system The SBC feedback can be from a relay contactor or from the mechanical brake itself Note If also the drive can control the brake the feedback must not be from the mechanical brake 1 10 9 8 7 6 5 4 3 2 X114 TP DO GND DI X113 M Diagnostic pulses DO GND ...

Page 293: ... 1 COM GND GND Physical separation of the different channels or appropriate cable protection eg double shielding Channel separation 24 V DC PNP outputs Diagnostic pulses from an active sensor must not be overlapping 1 10 9 8 7 6 5 4 3 2 X114 TP DO GND DI X113 CH 1 CH 2 COM GND GND Physical separation of the different channels or appropriate cable protection eg double shielding 24 V DC NPN inputs C...

Page 294: ...4 3 2 X114 TP DO GND DI X113 1 10 9 8 7 6 5 4 3 2 X114 TP DO GND DI X113 Physical separation of the different channels or appropriate cable protection eg double shielding Module 1 cascade master Module 2 Module 3 Common GND Common GND Common GND E stop button ACK button Channel separation Diagnostic pulses ...

Page 295: ...les of how to connect the FSO module to the ACS880 DCS880 drive WARNING Connect the FSO module to a 24 V DC power supply If you connect it to a power supply with a higher voltage for example 115 V or 230 V it will cause damage to the module If this occurs the module must be replaced ...

Page 296: ...r the power supply wires 5 mounting plate for ZCU 14 6 The default mounting plate for ZCU 12 is attached to the module user s manual not shown in the figure Examining the delivery Make sure that all parts are in the package and that there are no signs of damage Notify the shipper immediately if you find damaged parts Do not use damaged parts they must be replaced Make sure that the FSO module is o...

Page 297: ... from the FSO module and replace it with the other mounting plate in the package You can install the FSO module onto the control unit adjacent to the control unit If you do not install the module directly onto the control unit make sure that the module is correctly grounded For the requirements of the STO cable and data cable refer to STO cable and data cable between FSO module and drive on page 5...

Page 298: ...ling the module onto a ZCU control unit Install the FSO mechanically onto the control unit as described in the drive hardware manual For the tightening torques refer to Tightening torques on page 517 Examples are shown below ...

Page 299: ...annel 1 digital input 3 4 DI Channel 1 digital input 4 5 GND Signal ground 6 GND Signal ground 7 DO Channel 1 digital output 1 8 DO Channel 1 digital output 2 9 DO Channel 1 digital output 3 10 TP Channel 1 diagnostic pulse out X114 1 DI Channel 2 digital input 1 2 DI Channel 2 digital input 2 3 DI Channel 2 digital input 3 4 DI Channel 2 digital input 4 5 GND Signal ground 6 GND Signal ground 7 D...

Page 300: ...1 Stop the drive and do the steps in section Electrical safety precautions on page 14 before you start the work 2 Make sure that the FSO electronics grounding screw is correctly tightened See section Tightening torques on page 517 3 Make sure that the enclosure grounding screw is correctly tightened Use T10 head See section Tightening torques on page 517 2 3 2 3 ...

Page 301: ...Installation 301 4 Make sure that the FSO data cable terminal X110 is connected to the drive Use only the cable delivered with the module 4 4 ...

Page 302: ...e and data cable between FSO module and drive on page 517 6 Connect the digital inputs digital outputs diagnostic pulses and signal ground at the FSO terminals X113 and X114 according to the application requirements Use a tightening torque of 0 24 Nm 2 1 lbf in Use proper cable strain relief Use only the I O terminal blocks attached to the FSO module Make sure that the ground terminal maximum curr...

Page 303: ... Connect the power supply wires to the FSO terminal X112 Use a tightening torque of 0 24 Nm 2 1 lbf in for the FSO terminals Use proper cable strain relief See also section Power supply connection cables on page 289 7 7 ...

Page 304: ...304 Installation ...

Page 305: ...ists Check the mechanical and electrical installation of the FSO module before start up Go through the checklists below together with another person Read chapter Safety instructions before you work on the safety system WARNING Obey the safety instructions See chapter Safety instructions on page 13 If you ignore them injury or death can occur Stop the drive and do the steps in section Electrical sa...

Page 306: ...tallation area ELECTRICAL INSTALLATION See chapter Planning for installation and section Installation Electrical installation If a PELV power supply is used its ground has to be in the same potential as the drive ground Appropriate supply input power fuses are installed Data cable between the drive and the FSO module is routed separately from high power cables drive supply and motor cabling I O wi...

Page 307: ...e adequate expertise and knowledge of functional safety the safety functions as well as the configuration of the FSO module ABB has training courses available on the FSO module Password You need a password to be able to upload the parameters from the FSO and download the modified parameters from your PC to the FSO and the drive The password is set to 12345678 at the factory The password must conta...

Page 308: ...lain the main phases of the safety system configuring process 1 Risk assessment 2 Safety requirements 3 Planning the configuration of the FSO 4 Design of the safety functions 5 Commissioning of the FSO 6 Validation of the functional safety system 7 Validation test report 8 Modification 9 Decommissioning FSO configuring ...

Page 309: ...rameters of the FSO module commissioning of the safety encoder commissioning of the PROFIsafe connection to the safety PLC electrical installation etc 6 Validation of the functional safety system Validation of the safety functions which are used in the safety system They operate as required in the application and the safety requirements SRS arising from the risk assessment are fulfilled If any of ...

Page 310: ...on of the correct operation of the safety application See chapter Verification and validation 1 Plan the configuration parameter values according to the safety requirements of the system installation wiring etc These requirements should be based on the risk assessment of the application The configuration should take into account also the electrical design documents of the system 2 Set the paramete...

Page 311: ...all devices in the system for example switches light curtains and PLCs e After configuring all necessary functions do these two steps Download the configuration to the FSO button Download to FSO and validate A password is required Save the configuration to your PC button Save safety file f After downloading the FSO and the tool validate the configuration and the tool asks you to confirm the valida...

Page 312: ...Motor nominal speed 1360 0 rpm Use the same value with the drive parameter 99 09 Motor nominal speed and the value on the motor type designation label Note For a DCS880 drive the equivalent parameter is 99 14 M1 nominal base speed FSOGEN 51 Zero speed without encoder 90 0 rpm when an encoder is used FSOGEN 52 Zero speed with encoder Stopping functions are considered to be completed at this speed U...

Page 313: ...1 and it is installed in Slot 2 on the drive control board One HTL encoder is used Set these drive parameters in the Parameters view of the Drive composer pro PC tool The motor speed feedback during motor control is from Encoder 1 ACS880 90 41 Motor feedback selection Encoder 1 DCS880 90 41 M1 feedback selection Encoder 1 The drive generates a warning if an encoder failure occurs ACS880 90 45 Moto...

Page 314: ...drive STO function if there is a fault in the FSE module or with the safety encoder S_ENCGEN 11 FSE diagnostic failure reaction STO Cross comparison tolerance 5 rpm sets how much the shaft speed of the motor can change within 1 ms S_ENCGEN 14 Enc speed cross comp tolerance 5 rpm Rotation direction not changed S_ENCGEN 41 Gear numerator encoder 1 1 91 11 Module 1 type FSE 31 91 12 Module 1 location...

Page 315: ...how big the difference between the speed information in the internal channels 1 and 2 from FSE to FSO module can be If the difference is bigger FSO module goes into the fail state and stops the system safely STO The speed information is read from the FSE to FSO module through two channels of 1oo2 structure The channels may be out of sync by 1 ms This delay causes some speed difference between the ...

Page 316: ... DCS880 drive FSE module disabling steps 1 Set S_ENCGEN 01 Disable 2 Set 91 11 None 3 Set 200 232 None 4 Set 200 231 Disabled 5 Download the safety file to FSO module 6 Make sure that the encoder related parameters in drive parameter groups 91 92 are not locked any more This indicates that FSO is not using the encoder 7 Make sure that drive parameter 90 41 is set to Encoder 1 if motor control must...

Page 317: ...not active load See the subsections below Alternative 1 S_ENCGEN 11 STO The FSO module goes into the Fail safe state and actives the FSO STO function immediately when the encoder data is lost regardless of the status of the safety functions For more information see section FSO modes on page 60 Alternative 2 S_ENCGEN 11 No STO FSO module does not react to encoder fault unless there are active safet...

Page 318: ...This feature requires ACS880 primary control program version 2 51 or later Make sure that you configure all safety functions so that they operate correctly both with and without an encoder Note especially these parameters and restrictions You must set two zero speed limits FSOGEN 51 Zero speed without encoder and FSOGEN 52 Zero speed with encoder The SLS trip limits cannot be below these zero spee...

Page 319: ...ssivated due to safety fieldbus problems SBUSGEN 10 STO indication passivation Fault the FB module is connected to option slot 1 200 223 Safety fieldbus adapter slot FBA A and 50 01 FBA A enable 1 PROFIsafe profile ABB_PS1 in use PROFIsafe 12 PROFIsafe telegram type 0x221 IP address of the FB module 1 PROFIsafe 11 PROFIsafe F_Dest_Add 1 Configuring I O How to configure I O To configure the I O set...

Page 320: ...on indications on page 58 a safety relay the SBC function and a cascade loop User can select the output type single or redundant output and set the logic state for each digital output The logic state of output can be configured to be active low or active high For some of the safety functions output A and output B are available This enables the use of cascaded functions and the function specific in...

Page 321: ...13 10 Safety relay 2 feedback None Cascade A X113 1 X114 1 X113 7 X114 7 Safety relay 1 output DO X113 8 X114 8 Safety relay 1 feedback DI X113 4 DO diagnostic pulse period 59000 ms DO diagnostic pulse length 1 ms Safety relay 2 output None Cascade B None DI X113 1 diag pulse on off On DI X113 2 diag pulse on off On DI X113 3 diag pulse on off On DI X113 4 diag pulse on off On DI X114 1 diag pulse...

Page 322: ...system The SSE function is activated from a redundant digital input in the master FSO SSE 11 SSE input A DI X113 1 X114 1 The SSE function is cascaded back to the master FSO with a single digital input and output SSE 12 SSE input B DI X113 2 SSE 21 SSE output DO X113 8 The SSE function is cascaded with a single digital input and output in the follower FSOs SSE 12 SSE input B DI X113 2 SSE 21 SSE o...

Page 323: ...nt signal through the digital input defined by parameter FSOGEN 42 Acknowledgement button input SSE 11 SSE input A Sets the digital input that is connected to the primary input of the SSE function In this example this parameter sets the digital input that is used for the activation of the SSE function in the master FSO DI X113 1 X114 1 Redundant input X113 1 X114 1 SSE 12 SSE input B Sets the digi...

Page 324: ...324 Configuration FSOGEN 42 Acknowledg ement button input Sets the digital input that is connected to the button for acknowledgement operations DI X114 2 Single input X114 2 Index Name Value Description ...

Page 325: ...put defined by parameter FSOGEN 11 Stop completed output is active SSE 11 SSE input A Sets the digital input that is connected to the primary input of the SSE function In this example the activation of the SSE function in the follower FSOs comes from the master FSO through the cascade loop Cascade A and this parameter must be set to None None No input connected SSE 12 SSE input B Sets the digital ...

Page 326: ...utput X113 8 X114 8 SAFEIO 22 Safety relay 1 feedback Sets the digital feedback input of safety relay 1 DI X113 4 Single input X113 4 SAFEIO 23 Safety relay 1 feedback type Sets the type of the feedback signal for safety relay 1 Mechanically linked NC contacts Feedback of the safety relay is NC inverted state compared with the relay SAFEIO 24 Safety relay 2 output Sets the digital output for safet...

Page 327: ...before or at the same time with the drive STO function See section Safe torque off STO on page 67 SBC at trip limit hits The FSO module activates the SSE function after trip limit hits in the SLS SMS and SDI functions You can configure the SSE function either with immediate STO stop category 0 or with emergency ramp stop category 1 see section Safe stop emergency SSE on page 106 If you want that t...

Page 328: ...328 Configuration FSO internal fault situations The FSO module activates STO and SBC if configured into use in internal fault situations ...

Page 329: ...ime It the value is positive the FSO activates the SBC after the drive STO See section How to configure SBC after STO on page 333 If the value is negative the FSO activates the SBC before the drive STO See section How to configure SBC before STO on page 335 3 If you use the speed limit activated SBC function set the correct SBC speed limit with parameter SBC 14 STO SBC speed The drive STO function...

Page 330: ...C before STO on page 347 If the value is zero 0 ms or positive the FSO activates the SBC and drive STO functions at the same time when the speed limit is reached Note If parameter SBC 11 STO SBC usage is Delayed brake the same parameter SBC 12 STO SBC delay is used also in the STO and SSE with immediate STO functions see section How to configure the SBC in the STO function on page 329 In the SS1 a...

Page 331: ... to zero speed to a suitable value according to your application How to configure STO Example 1 without an encoder The figure below shows an example of a simple STO function set up when an encoder is not used redundant emergency stop button connected to input STO 11 STO input A DI X113 1 X114 1 automatic acknowledgement STO 02 STO acknowledgement Automatic estimated time in which the motor coasts ...

Page 332: ...c acknowledgement STO 02 STO acknowledgement Automatic zero speed limit where STO function is completed and it can be acknowledged is 40 rpm parameter FSOGEN 52 Zero speed with encoder 40 rpm the fly start feature is in use that is you can restart the drive before the motor has stopped STO 13 Restart delay after STO 1000 ms no output connected no brake SBC 11 STO SBC usage None STO 11 DI X113 1 X1...

Page 333: ...otor before it has stopped STO 13 Restart delay after STO 1300 ms brake connected to redundant output diagnostic pulses activated SBC 21 SBC output DO X113 7 X114 7 SAFEIO 53 and SAFEIO 56 On SAFEIO 21 Safety relay 1 output DO X113 7 X114 7 STO is activated if brake feedback fails SBC 22 SBC feedback action STO feedback from the brake is connected to digital input X113 2 SAFEIO 22 Safety relay 1 f...

Page 334: ... start the motor before it has stopped STO 13 Restart delay after STO 1300 ms brake connected to redundant output diagnostic pulses activated SBC 21 SBC output DO X113 7 X114 7 SAFEIO 53 and SAFEIO 56 On SAFEIO 21 Safety relay 1 output DO X113 7 X114 7 STO is activated if brake feedback fails SBC 22 SBC feedback action STO feedback from the brake is connected to digital input X113 2 SAFEIO 22 Safe...

Page 335: ...d 1200 ms brake connected to redundant output diagnostic pulses activated SBC 21 SBC output DO X113 7 X114 7 SAFEIO 53 and SAFEIO 56 On SAFEIO 21 Safety relay 1 output DO X113 7 X114 7 STO is activated if brake feedback fails SBC 22 SBC feedback action STO brake feedback input connected to input SAFEIO 22 Safety relay 1 feedback DI X113 2 feedback input type NC inverted state compared with the bra...

Page 336: ... with encoder 40 rpm brake connected to redundant output diagnostic pulses activated SBC 21 SBC output DO X113 7 X114 7 SAFEIO 53 and SAFEIO 56 On SAFEIO 21 Safety relay 1 output DO X113 7 X114 7 STO is activated if brake feedback fails SBC 22 SBC feedback action STO brake feedback input connected to input SAFEIO 22 Safety relay 1 feedback DI X113 2 feedback input type NC inverted state compared w...

Page 337: ...C usage Speed limit SBC 14 STO SBC speed 60 rpm zero speed limit where STO function is completed and it can be acknowledged is 40 rpm parameter FSOGEN 52 Zero speed with encoder 40 rpm redundant emergency stop button connected to input STO 11 STO input A DI X113 1 X114 1 automatic acknowledgement STO 02 STO acknowledgement Automatic the fly start feature is in use that is you can restart the drive...

Page 338: ...ted Inputs Outputs STO 02 Automatic STO 21 None STO 22 None SBC 21 DO X113 7 X114 7 SBC 11 Speed limit SBC 22 STO SAFEIO 23 Mechanically linked NC contacts STO 11 DI X113 1 X114 1 STO 12 None SBC 14 60 rpm FSOGEN 52 40 rpm SAFEIO 53 SAFEIO 56 On SAFEIO 22 DI X113 2 STO 13 500 ms SAFEIO 21 DO X113 7 X114 7 ...

Page 339: ...lure the FSO module goes into the Fail safe mode and actives the STO with speed limit activated SBC function with Delayed brake see above If parameter S_ENCGEN 11 FSE diagnostic failure reaction Est switch not active load the FSO module continues operation by using the estimated motor speed until the encoder failure is fixed and the exact motor speed is available again Note Safe speed estimate can...

Page 340: ...onitored ramp SS1 13 SS1 type SS1 t delay for STO activation after SS1 request 2000 ms SS1 14 SS1 t delay for STO 2000 ms automatic acknowledgement STO 02 STO acknowledgement Automatic redundant emergency stop button connected to input SS1 11 SS1 input A DI X113 1 X114 1 single output connected SS1 21 SS1 output DO X114 9 zero speed limit where SS1 function is completed and drive STO activated is ...

Page 341: ...S1 11 DI X113 1 X114 1 SS1 12 None SS1 21 DO X114 9 SS1 22 None SS1 13 SS1 t FSOGEN 51 90 rpm SS1 14 2000 ms Time Speed Inputs Outputs SS1 activated STO activated SS1 01 Version 1 STO 02 Automatic SBC 15 0 rpm SS1 15 0 ms ...

Page 342: ...le output connected SS1 21 SS1 output DO X114 9 zero speed limit where SS1 function is completed and drive STO activated is 90 rpm FSOGEN 51 Zero speed without encoder 90 rpm when an encoder is used FSOGEN 52 Zero speed with encoder 90 rpm delay for activating STO after the zero speed limit has been reached 0 ms SS1 15 SS1 r ramp zero speed delay for STO 0 ms speed limit activated brake not in use...

Page 343: ...11 SS1 input A DI X113 1 X114 1 single output connected SS1 21 SS1 output DO X114 9 brake connected to redundant output diagnostic pulses activated SBC 21 SBC output DO X113 7 X114 7 SAFEIO 53 and SAFEIO 56 On SAFEIO 21 Safety relay 1 output DO X113 7 X114 7 speed limit activated brake in use speed below which the brake and STO are activated 180 0 rpm SBC 15 SSE SS1 SBC speed 180 rpm delay for act...

Page 344: ... 13 SS1 t SS1 01 Version 1 STO 02 Automatic SS1 21 DO X114 9 SS1 22 None SS1 11 DI X113 1 X114 1 SS1 12 None SBC 15 180 rpm SBC 22 STO SAFEIO 23 Mechanically linked NC contacts SAFEIO 22 DI X113 2 SS1 15 0 ms SBC 21 DO X113 7 X114 7 SAFEIO 53 SAFEIO 56 On SS1 14 2000 ms SBC 13 1200 ms SAFEIO 21 DO X113 7 X114 7 ...

Page 345: ...tput DO X113 7 X114 7 speed limit activated brake in use speed limit below which the brake and STO are activated 180 0 rpm SBC 15 SSE SS1 SBC speed 180 rpm delay for activating STO after brake is zero STO and SBC are activated at the same time SBC 12 STO SBC delay 0 ms delay for activating the brake and STO after the SBC speed limit has been reached 0 ms SS1 15 SS1 r ramp zero speed delay for STO ...

Page 346: ...ted SS1 13 SS1 r SS1 01 Version 1 STO 02 Automatic SS1 21 DO X114 9 SS1 22 None SS1 11 DI X113 1 X114 1 SS1 12 None SBC 15 180 rpm SBC 22 STO SAFEIO 23 Mechanically linked NC contacts SAFEIO 22 DI X113 2 SS1 15 0 ms SBC 21 DO X113 7 X114 7 SAFEIO 53 SAFEIO 56 On SBC 13 1200 ms SAFEIO 21 DO X113 7 X114 7 ...

Page 347: ...ored ramp SS1 13 SS1 type SS1 t SAR1 emergency ramp 200 112 SAR1 ramp time to zero always with the SS1 function see section Configuring SAR on page 361 delay for STO activation after SS1 request 2000 ms SS1 14 SS1 t delay for STO 2000 ms automatic acknowledgement STO 02 STO acknowledgement Automatic redundant emergency stop button connected to input SS1 11 SS1 input A DI X113 1 X114 1 single outpu...

Page 348: ...vated if brake feedback fails SBC 22 SBC feedback action STO brake feedback input connected to input SAFEIO 22 Safety relay 1 feedback DI X113 2 feedback input type NC inverted state compared with the brake relay SAFEIO 23 Safety relay 1 feedback type Mechanically linked NC contacts See also section Configuring mute times on page 393 Note This figure shows the case when an encoder is not used Reme...

Page 349: ...C 15 SSE SS1 SBC speed 180 rpm delay for activating STO after brake 300 ms only a negative delay is possible the SBC is activated before STO SBC 12 STO SBC delay 300 ms Note The same SBC delay is used in the STO and SS1 SSE functions delay for activating the brake after the SBC speed limit has been reached 0 ms SS1 15 SS1 r ramp zero speed delay for STO 0 ms not shown in the figure when an encoder...

Page 350: ...time or ramp monitoring See section Configuring STO on page 331 Remember to configure SAR1 Time Speed SBC activated Inputs Outputs SS1 activated SS1 13 SS1 r SS1 01 Version 1 STO 02 Automatic SS1 21 DO X114 9 SS1 22 None SS1 11 DI X113 1 X114 1 SS1 12 None SBC 15 180 rpm SBC 22 STO SAFEIO 23 Mechanically linked NC contacts SAFEIO 22 DI X113 2 SS1 15 0 ms SBC 21 DO X113 7 X114 7 SAFEIO 53 SAFEIO 56...

Page 351: ... figure below shows an example of the SSE function with immediate STO set up when an encoder is not used drive STO is activated immediately after the SSE request SSE 13 SSE function Immediate STO automatic acknowledgement STO 02 STO acknowledgement Automatic redundant emergency stop button connected to input SSE 11 SSE input A DI X113 1 X114 1 no outputs connected delay for restarting the drive 15...

Page 352: ...nction Immediate STO automatic acknowledgement STO 02 STO acknowledgement Automatic redundant emergency stop button connected to input SSE 11 SSE input A DI X113 1 X114 1 no outputs connected zero speed limit where STO function is completed and it can be acknowledged is 40 rpm parameter FSOGEN 52 Zero speed with encoder 40 rpm no brake SBC 11 STO SBC usage None SSE 13 Immediate STO SSE activated T...

Page 353: ...2 How to configure SSE with immediate STO with speed limit activated SBC This safety function requires that an encoder is used Configure the safety encoder interface first see section Configuring the safety encoder interface on page 313 The configuration is identical to the STO with speed limit activated SBC function with these differences parameter STO 13 Restart delay after STO is not used SSE i...

Page 354: ...ant emergency stop button connected to input SSE 11 SSE input A DI X113 1 X114 1 single output connected SSE 21 SSE output DO X113 9 zero speed limit where SSE function is completed and drive STO activated is 90 rpm FSOGEN 51 Zero speed without encoder 90 rpm when an encoder is used FSOGEN 52 Zero speed with encoder 90 rpm delay for activating the drive STO after the speed limit has been reached 0...

Page 355: ...113 1 X114 1 single output connected SSE 21 SSE output DO X113 9 zero speed limit where SSE function is completed and drive STO activated is 90 rpm FSOGEN 51 Zero speed without encoder 90 rpm when an encoder is used FSOGEN 52 Zero speed with encoder 90 rpm delay for activating the drive STO after the zero speed limit has been reached 0 ms SSE 16 SSE ramp zero speed delay for STO 0 ms speed limit a...

Page 356: ... ms SSE 15 SSE delay for STO 2000 ms redundant emergency stop button connected to input SSE 11 SSE input A DI X113 1 X114 1 single output connected SSE 21 SSE output DO X113 9 brake connected to redundant output diagnostic pulses activated SBC 21 SBC output DO X113 7 X114 7 SAFEIO 53 and SAFEIO 56 On SAFEIO 21 Safety relay 1 output DO X113 7 X114 7 speed limit activated brake in use speed below wh...

Page 357: ...d SSE 11 DI X113 1 X114 1 SSE 12 None SSE 21 DO X113 9 SSE 22 None SSE 14 Time SSE 13 Emergency ramp STO 02 Automatic SBC 15 240 rpm SSE 16 0 ms SBC 22 STO SAFEIO 23 Mechanically linked NC contacts SAFEIO 22 DI X113 2 SAFEIO 53 SAFEIO 56 On SBC 21 DO X113 7 X114 7 SSE 15 2000 ms SAFEIO 21 DO X113 7 X114 7 ...

Page 358: ...ated SBC 21 SBC output DO X113 7 X114 7 SAFEIO 53 and SAFEIO 56 On SAFEIO 21 Safety relay 1 output DO X113 7 X114 7 speed limit activated brake in use speed below which the brake and STO are activated 240 0 rpm SBC 15 SSE SS1 SBC speed 240 rpm delay for activating STO after brake is zero STO and SBC are activated at the same time SBC 12 STO SBC delay 0 ms delay for activating the brake and drive S...

Page 359: ...activated SSE 11 DI X113 1 X114 1 SSE 12 None SSE 21 DO X113 9 SSE 22 None SSE 14 Ramp SSE 13 Emergency ramp STO 02 Automatic SBC 15 240 rpm SSE 16 0 ms SBC 22 STO SAFEIO 23 Mechanically linked NC contacts SAFEIO 53 SAFEIO 56 On SBC 21 DO X113 7 X114 7 SAFEIO 21 DO X113 7 X114 7 SAFEIO 22 DI X113 2 ...

Page 360: ...O activation after SSE request is set with parameter SSE 15 SSE delay for STO delay for activating the brake after the speed limit has been reached is set with parameter SSE 16 SSE ramp zero speed delay for STO Note If you configure the SSE with speed limit activated SBC function this activates the same function in the SS1 function see section How to configure SS1 with speed limit activated SBC SB...

Page 361: ...eed to zero 1000 ms 200 112 SAR1 ramp time to zero 1000 ms Scaling speed 1500 rpm 200 202 SAR speed scaling 1500 rpm initial range for monitoring 100 ms SARx 02 SAR initial allowed range 100 ms minimum allowed ramp time 500 ms SARx 21 SAR1 min ramp time to zero 500 ms maximum allowed ramp time 1000 ms SARx 12 SAR1 max ramp time to zero 1500 ms Note If you use SAR1 in several safety functions at th...

Page 362: ...oring SLS activation delay 2000 ms SLSx 04 SLS time delay 2000 ms automatic acknowledgement SLSx 02 SLS acknowledgement Automatic redundant SLS activation button connected to input SLSx 11 SLS1 input A DI X113 2 X114 2 single output connected SLSx 15 SLS1 output A DO X114 7 positive limits SLS 1200 0 rpm trip limit 1320 0 rpm 200 23 SLS1 limit positive 1200 rpm SLSx 14 SLS1 trip limit positive 132...

Page 363: ... 15 DO X114 7 SLSx 16 None SLSx 03 Time SLSx 02 Automatic SLSx 04 2000 ms SLSx 13 1020 rpm 200 23 1200 rpm SLSx 14 1320 rpm 200 22 900 rpm SLS1 Time Speed Inputs Outputs SLS activated SLS monitoring started typical 200 21 Version 1 SLS monitoring started latest ...

Page 364: ...SLS2 input DI X113 2 X114 2 single output connected SLSx 24 SLS2 output DO X114 7 positive limits SLS 1200 0 rpm trip limit 1320 0 rpm 200 33 SLS2 limit positive 1200 rpm SLSx 23 SLS2 trip limit positive 1320 rpm negative limits SLS 900 0 rpm trip limit 1020 0 rpm 200 32 SLS2 limit negative 900 rpm SLSx 22 SLS2 trip limit negative 1020 rpm See also section Configuring mute times on page 393 Note T...

Page 365: ...toring limit during the deceleration ramp SLS with ramp monitoring See section Configuring STO on page 331 The FSO module activates the SSE function if the motor speed hits a trip limit See section Configuring SSE on page 351 SLSx 24 DI X113 2 X114 2 SLSx 24 DO X114 7 SLSx 03 Ramp SLSx 02 Automatic Remember to configure SAR1 SLS2 Time Speed Input Output SLS activated SLS monitoring started 200 31 ...

Page 366: ...imits are changed it affects the Variable SLS limits and trip limits For more information on the Variable SLS function see page 172 How to configure Variable SLS with time monitoring Example The figure below shows an example of the Variable SLS function with time monitoring set up Variable SLS function activated 200 61 SLS variable activity and version Version 1 automatic acknowledgement SLSx 02 S...

Page 367: ...ogram only positive limits are scaled Positive_Scaling 0 Negative_Scaling 1 scaling values from the safety PLC 70 50 100 value set in Variable_SLS_limit 7000 5000 10000 SLSx 51 DO X113 7 200 53 1200 rpm SLSx 43 1320 rpm Speed Time Output varSLS activated 70 scaling New scaling values from PLC 50 100 200 61 Version 1 SLSx 03 Time SLSx 02 Automatic SLSx 04 2000 ms ...

Page 368: ...arameters acceleration ramp according to drive parameters single output connected SLSx 51 Variable SLS output DO X114 7 positive limits SLS 1200 0 rpm trip limit 1320 0 rpm 200 53 SLS4 limit positive 1200 rpm SLSx 43 SLS4 trip limit positive 1320 rpm negative limits SLS 100 0 rpm trip limit 150 0 rpm FSOGEN 51 Zero speed without encoder or when an encoder is used FSOGEN 52 Zero speed with encoder ...

Page 369: ... 50 100 value set in Variable_SLS_limit 7000 5000 10000 See also section SLS reaction when modulation is lost during deceleration ramp with ramp monitoring on page 147 Speed Time Output varSLS activated 70 scaling New scaling values from PLC 50 100 Remember to configure SAR1 SLSx 51 DO X113 7 200 53 1200 rpm SLSx 43 1320 rpm 200 61 Version 1 SLSx 03 Ramp SLSx 02 Automatic ...

Page 370: ...ce between the scaled limits is the same as the original difference See Example 1 below If the difference between original SLS4 and SLS4 trip limits 25 rpm the difference between the limits is at least 25 rpm See Example 2 below Regardless of the original difference between the limits the scaled SLS4 trip limit must always be at least the zero speed value parameter FSOGEN 51 If an encoder is used ...

Page 371: ...riginal SLS4 limit 100 rpm Original SLS4 trip limit 150 rpm Zero speed value 12 rpm In this case the difference between original SLS4 and SLS4 trip limits is greater than 25 rpm SLS4 limit and trip limit are scaled down normally from 100 to 50 When the scaling value is 50 the difference between the limits is 25 rpm and it stays A Scaled SLS4 trip limit B Scaled SLS4 limit C Zero speed value FSOGEN...

Page 372: ...ween original SLS4 and SLS4 trip limits is greater than 5 rpm SLS4 limit and trip limit are scaled down normally from 100 to 50 When the scaling value is 50 the difference between the limits is 5 rpm and it stays A Scaled SLS4 trip limit B Scaled SLS4 limit C Zero speed value FSOGEN 51 D The difference between SLS4 limits is 50 rpm when the scaling value is 100 E The difference between the scaled ...

Page 373: ...vates the STO function if the motor speed hits a ramp monitoring limit during the deceleration ramp Variable SLS with ramp monitoring See section Configuring STO on page 331 The FSO module activates the SSE function if the motor speed hits a trip limit See section Configuring SSE on page 351 A Scaled SLS4 trip limit B Scaled SLS4 limit C Zero speed value D The difference between SLS4 limits is 10 ...

Page 374: ...formation on the SMS function see page 177 How to configure SMS version 1 Example The figure below shows an example of the SMS version 1 set up SMS function version 1 activated 200 71 SMS activity and version Version 1 positive limit 1800 0 rpm SMS 14 SMS trip limit positive 1800 rpm negative limit 1200 0 rpm SMS 13 SMS trip limit negative 1200 rpm SSE function configured as immediate STO SSE 13 S...

Page 375: ...00 rpm SSE function configured as immediate STO SSE 13 SSE function Immediate STO See also section Configuring mute times on page 393 Note If you also use an SLS function the SMS positive and negative trip limits must be more than the speed defined by the corresponding SLS positive trip limit and less than the speed defined by the corresponding SLS negative trip limit respectively Related safety f...

Page 376: ... X113 1 X114 1 delay for POUS complete indication 0 POUS 13 POUS delay for completion 0 ms POUS completed output for example an indication lamp connected to single output X114 9 POUS 22 POUS completed output DO X114 9 How to configure SLS function behavior when drive modulation is lost When it is critical for the process that the drive must be able to indicate safely if the drive modulation is los...

Page 377: ...amp with time monitoring on page 157 How to configure SLSn with time monitoring if drive modulation is lost during SLS deceleration ramp Example 1 The figure below shows an example of the modoff situation with SLS function with time monitoring when Modoff delay time parameter SLSx 05 is selected Basic parametrization of the SLS function made according to chapter Configuring SLS on page 362 Modoff ...

Page 378: ...ction triggers STO function regardless of the configuration of the SSE function STO indication goes on STO 21 STO output DO X113 7 4 SLS time monitoring limit SLSx 04 SLS time delay 2000 ms 5 STO 14 delay starts when drive modulation is lost If modulation does not return SLS indication goes on after STO 14 delay has elapsed Example 2 The figure below shows an example of the modoff situation with S...

Page 379: ...t speed when SLS time monitoring limit has elapsed SLSx 04 SLS time delay 2000 ms STO indication goes on STO 21 STO output DO X113 7 see chapter How to configure STO on page 331 4 STO 14 delay starts when drive modulation is lost If modulation does not return SLS indication goes on after STO 14 delay has elapsed When drive modulation is lost last valid speed estimate is stored to FSO module until ...

Page 380: ...modulation is lost SLSx 05 SLS ramp modoff reaction Monitoring active and modoff delay time Modoff delay time SLSx 06 SLS ramp modoff delay time 300 ms Relevant parameters for this configuration Deceleration time drive parameter 23 13 Deceleration time 1 SLS activation delay 2000 ms SLSx 04 SLS time delay 2000 ms STO 14 Time to zero speed with STO and modoff 2500 ms Motor speed Time 1 6 5 3 4 2 B ...

Page 381: ... indication goes on SLSx 15 SLS1 output A DO X114 7 6 The SLSx 04 time monitoring limit SLS indication is activated at the latest Time monitoring is kept active also when modulation is lost during SLS deceleration ramp and SLSx 06 SLS ramp modoff delay time is set shorter than SLSx 04 SLS time delay FSO indicates SLS hit and STO is activated when SLSx 06 has elapsed Drive restart is possible until...

Page 382: ...tion of the drive does not return After STO 14 has elapsed SLS indication goes on SLSx 15 SLS1 output A DO X114 7 The time monitoring of the SLS function is disabled when modulation of the drive is lost during SLS deceleration ramp When the drive stops modulation FSO disables the time monitoring of the SLS function and starts to wait that the motor will coast to zero speed STO 14 Time to zero spee...

Page 383: ...modoff delay time 200 ms Relevant parameters for this configuration Scaling speed 1500 rpm 200 202 SAR speed scaling 1500 rpm Deceleration time and ramp monitoring according to SAR1 parameters ramp time from Scaling speed to zero 1000 ms 200 112 SAR1 ramp time to zero 1000 ms initial range for monitoring 100 ms SARx 02 SAR initial allowed range 100 ms minimum allowed ramp time 500 ms SARx 21 SAR1 ...

Page 384: ...p modoff delay time 200 ms 3 Modulation of the drive has not returned before the SLS ramp modoff delay time has elapsed SLSx 06 SLS ramp modoff delay time 200 ms FSO activates STO function STO indication goes on STO 21 STO output DO X113 7 4 STO 14 delay starts when drive modulation is lost If modulation does not return SLS indication goes on after STO 14 delay has elapsed When drive modulation is...

Page 385: ...modoff 2500 ms 1 SLS request is activated SLSx 11 SLS1 input A DI X113 2 X114 2 SLS ramp monitoring is activated SAR1 Parameter 200 202 SAR speed scaling 1500 rpm is used as a reference point in ramp time calculations Deceleration towards the SLS limit speed is started according to SAR1 parameters ramp time from Scaling speed to zero 1000 ms 200 112 SAR1 ramp time to zero 1000 ms initial range for...

Page 386: ...ation is lost last valid speed estimate is stored to FSO module until modulation comes back or monitoring limit is reached Ramp monitoring is kept active also when modulation is lost during SLS deceleration ramp The ramp monitoring is activated when SLS is requested Note It is also possible to use fixed delay time until tripping fault without time ramp monitoring by setting SLSx 05 to Modoff delay...

Page 387: ... SSMx on page 435 You can use the SSM function either with a safety encoder or with a safe speed estimate For more information on the SSM function see page 182 If you use an encoder you must configure the encoder interface first see section Configuring the safety encoder interface on page 313 Note Depending on the application set the negative and positive SSM limits separately ...

Page 388: ...t connected SSMx 14 SSM1 output DO X114 7 SSM1 positive limit 1800 0 rpm SSMx 13 SSM1 limit positive 1800 rpm SSM1 negative limit 0 rpm SSMx 12 SSM1 limit negative 0 rpm When an encoder is not used Time to zero speed 1500 ms This is the estimated time in which the motor coasts to a stop from the maximum speed STO 14 Time to zero speed with STO and modoff 1500 ms not shown in the figure SSMx 11 DI ...

Page 389: ... appropriate values using the Drive composer pro PC tool See parameter group SDI on page 431 This safety function requires that an encoder is used Configure the encoder interface first see section Configuring the safety encoder interface on page 313 For more information on the SDI function see page 186 ...

Page 390: ...time monitoring SDI activation delay 2000 ms SDI 12 SDI delay 2000 ms SDI tolerance into the forbidden direction 2 degrees SDI 14 SDI tolerance limit degree 2 deg automatic acknowledgement SDI 13 SDI acknowledgement Automatic redundant activation button connected to input SDI 21 SDI positive input A DI X113 2 X114 2 single output connected SDI 23 SDI positive output A DO X114 7 SDI 21 DI X113 2 X1...

Page 391: ...ers see section Configuring SAR on page 361 SDI tolerance into the forbidden direction 2 degrees SDI 14 SDI tolerance limit degree 2 deg automatic acknowledgement SDI 13 SDI acknowledgement Automatic redundant activation button connected to input SDI 21 SDI positive input A DI X113 2 X114 2 single output connected SDI 23 SDI positive output A DO X114 7 SDI 21 DI X113 2 X114 2 SDI 22 None SDI 23 DO...

Page 392: ...ction Configuring SAR on page 361 The FSO module activates the STO function if the motor speed hits a ramp monitoring limit during the deceleration ramp SDI with ramp monitoring See section Configuring STO on page 331 The FSO module activates the SSE function if the motor rotation reaches the SDI tolerance limit degree See section Configuring SSE on page 351 ...

Page 393: ...ature see Mute time feature on page 64 How to determine values for mute time parameters The suitable values for mute times can be determined by monitoring FSO speed signals 200 01 FSO speed ch1 200 02 FSO speed ch2 with the Drive composer pro tool If possible all transient situations within the whole speed range of the application should be monitored Based on the results the mute times should be s...

Page 394: ...pecific mute time is disabled parameter FSOGEN 39 or if encoder is used parameter FSOGEN 39 Enable SMS mute time Disabled parameter FSOGEN 31 Transient mute time 100 ms Note When a synchronous machine is started there is a possibility of short 100 ms error spikes in safe speed estimate which can cause an unnecessary trip if the mute time is set too short If the motor is rotated only in positive di...

Page 395: ...more complex systems which cannot be properly configured with general transient mute time This example covers safe speed estimate trip limit situations with acceleration of an induction motor It is possible that safe speed estimate goes above the SLS trip limit for limited time when an induction machine is accelerated with high load inertia In Actual speed Safe speed estimate SMS trip limits 1 Err...

Page 396: ...the SLSx mute times are enabled with parameter FSOGEN 38 Enable SLSx mute times Trip limit hit in the SMS function when the SMS mute time SMS 17 is enabled with parameter FSOGEN 39 Enable SMS mute time Actual speed Safe speed estimate SLS1 trip limit positive SLSx 14 1 Amount of slip in safe speed estimate during acceleration 2 Safe speed estimate exceeds the SLS trip limit 3 Safe speed estimate r...

Page 397: ...ter SBC 12 STO SBC delay is configured in the STO function With an encoder parameter FSOGEN 32 Zero speed delay time 20 ms Without an encoder parameter FSOGEN 31 Transient mute time 20 ms Note If the SBC delay parameter SBC 12 STO SBC delay is positive or zero 0 ms the SBC and STO functions are activated at the same time Time Speed Zero speed limit reached FSOGEN 52 or FSOGEN 51 90 rpm Mute time e...

Page 398: ...ote If the SBC delay parameter SBC 12 STO SBC delay is positive or zero 0 ms the SBC and STO functions are activated at the same time Example 2 SBC speed limit parameter SBC 14 STO SBC speed is reached in the STO function and SSE with immediate STO requires an encoder With an encoder parameter FSOGEN 32 Zero speed delay time 20 ms Time Speed SBC delay elapsed STO activated FSOGEN 32 or FSOGEN 31 2...

Page 399: ...SLS trip limit With an encoder parameter FSOGEN 33 Monitoring start delay 20 ms Without an encoder parameter FSOGEN 31 Transient mute time 20 ms 1 SLS request activated 2 Safe speed in the middle of SLS and SLS trip limits 3 SLS monitoring started SLS indication activates SLSx 15 SLSx 16 2 Speed Time 3 FSOGEN 33 or FSOGEN 31 20 ms SLSx 14 1320 rpm 200 23 1200 rpm SLS1 request SLS1 indication 1 ...

Page 400: ...400 Configuration ...

Page 401: ...in the Safety settings window of the Drive composer pro PC tool Note The factory default values shown in the table can be different from the pre set parameter values in a delivered FSO ordered with a plus code eg Q972 For more information see section Factory reset on page 511 Note ABB recommends that you set drive parameter 31 22 STO indication run stop to value 3 4 or 5 This setting prevents the ...

Page 402: ...ersion 1 Activates version 1 of the SLS1 function 200 22 SLS1 limit negative Sets the SLS1 negative speed limit for the drive 0 0 rpm 35880 0 0 0 rpm Speed 200 23 SLS1 limit positive Sets the SLS1 positive speed limit for the drive 0 0 rpm 0 0 35880 0 rpm Speed 200 31 SLS2 activity and version Activates or deactivates the SLS2 function and shows the version of the SLS2 function Disabled Disabled D...

Page 403: ...s on page 370 0 0 rpm 0 0 35880 0 rpm Speed 200 61 SLS variable activity and version Activates or deactivates the Variable SLS function and shows the version of the Variable SLS function Note This function can be activated only when the safety fieldbus is installed Disabled Disabled Deactivates the Variable SLS function Version 1 Activates version 1 of the Variable SLS function 200 71 SMS activity...

Page 404: ...speed 200 202 SAR speed scaling to zero Note With value 0 ms the drive parameter 23 23 Emergency stop time defines the safe stop ramp The FSO module monitors the actual ramp using SAR1 parameters ramp monitoring or parameter SS1 14 SS1 t delay for STO time monitoring 1 ms 0 1 800 000 ms Time 200 201 Drive general settings version Shows the version of the drive general safety settings includes para...

Page 405: ... in the single encoder case also the channel that it is connected to Note ACS880 primary control program version 2 21 supports only one safety pulse encoder Note DCS880 firmware version 2 07 supports only one safety pulse encoder This parameter is read only Single encoder CH1 Single encoder CH1 200 254 CRC of the configuration Shows the FSO configuration checksum 0 0 65535 Checksum FSOGEN General ...

Page 406: ...zero speed limit is reached When an encoder is used This parameter is used only in ramp monitoring and trip limit hit situations 0 ms 0 1000 ms Time FSOGEN 32 Zero speed delay time Sets the time for how long the motor speed must stay inside zero speed limits in order to determine the motor as stopped Note This parameter is relevant only when an encoder is used Without an encoder parameter FSOGEN 3...

Page 407: ...41 Power up acknowledgement Sets the power up acknowledgement method Note If a safety function request is active when the FSO module is rebooted the request must be removed before the power up acknowledgement is accepted Manual Manual The FSO module reads an external acknowledgement signal through the digital input defined by parameter FSOGEN 42 Acknowledgement button input Automatic The FSO modul...

Page 408: ...or safe stopping functions Used to define when the safety function is completed and can be acknowledged Note This is the absolute value The same value is used in both positive and negative directions Note You cannot set trip limits below this value Note It is recommended to use a value higher than 0 5 rpm 0 0 rpm 0 0 600 0 rpm Speed FSOGEN 61 STO indication ext request Sets the type of the event t...

Page 409: ...cknowledgement methods on page 55 for more information on different acknowledgement methods Manual Manual The FSO module reads the external STO acknowledgement signal through the digital input defined by parameter FSOGEN 42 Acknowledgement button input The FSO module accepts the acknowledgement after the STO SSE or SS1 request has been removed and the stop function is completed output defined by p...

Page 410: ...3 3 Single input X113 3 DI X113 4 Single input X113 4 DI X114 1 Single input X114 1 DI X114 2 Single input X114 2 DI X114 3 Single input X114 3 DI X114 4 Single input X114 4 STO 12 STO input B Sets the digital input that is connected to the secondary input of the STO function The secondary input is mostly used for the cascade connection See parameters SAFEIO 12 Cascade A and SAFEIO 13 Cascade B No...

Page 411: ...therwise you have to make sure that the motor shaft has stopped rotating by other means eg visually Acknowledgement is allowed after coast stop in the STO SSE and SS1 functions when SBC is not used If SBC is used see parameter SBC 13 SBC time to zero speed If an external request activates the STO function this parameter sets the time after which the function is completed and the STO completed indi...

Page 412: ...that indicates the completion of the STO function See the diagrams in section Safe torque off STO on page 67 None None No output connected DO X113 7 X114 7 Redundant output X113 7 X114 7 DO X113 8 X114 8 Redundant output X113 8 X114 8 DO X113 9 X114 9 Redundant output X113 9 X114 9 DO X113 7 Single output X113 7 DO X113 8 Single output X113 8 DO X113 9 Single output X113 9 DO X114 7 Single output ...

Page 413: ... 12 STO SBC delay Sets the time when the SBC function will be activated in relation to the activation of the STO function A negative value means that the FSO module activates the SBC before the drive STO function If the value is 0 ms the FSO activates the drive STO and SBC functions at the same time STO function and SSE with immediate STO This parameter is valid if parameter SBC 11 STO SBC usage h...

Page 414: ... and the FSO module activates the STO and SBC functions 3 600 000 ms 0 3 600 000 ms Time SBC 14 STO SBC speed Sets the speed limit below which the FSO module activates the brake SBC in the STO function Requires that an encoder is used and parameter SBC 11 STO SBC usage is set to value Speed limit If the value is 0 0 rpm this feature is not in use Note This is the absolute value The same value is u...

Page 415: ...tput X113 9 X114 9 DO X113 7 Single output X113 7 DO X113 8 Single output X113 8 DO X113 9 Single output X113 9 DO X114 7 Single output X114 7 DO X114 8 Single output X114 8 DO X114 9 Single output X114 9 POUS Parameters for the POUS function POUS 01 POUS activity and version Activates or deactivates the POUS function and shows the version of the POUS function Disabled Disabled Deactivates the POU...

Page 416: ...3 3 Single input X113 3 DI X113 4 Single input X113 4 DI X114 1 Single input X114 1 DI X114 2 Single input X114 2 DI X114 3 Single input X114 3 DI X114 4 Single input X114 4 POUS 13 POUS delay for completion Sets the delay for the activation of the POUS complete indication after the POUS request 0 ms 0 3 600 000 ms Time POUS 21 POUS output Sets the digital output that indicates the activity of the...

Page 417: ...e output X114 7 DO X114 8 Single output X114 8 DO X114 9 Single output X114 9 41 SSE Parameters for the SSE function SSE 01 SSE version Shows the version of the SSE function Version 1 Version 1 Version 1 SSE 11 SSE input A Sets the digital input that is connected to the primary input of the SSE function None None No input connected DI X113 1 X114 1 Redundant input X113 1 X114 1 DI X113 2 X114 2 Re...

Page 418: ... Immediate STO The FSO module activates the drive STO immediately after the SSE request Emergency ramp The FSO module activates the drive STO after an emergency ramp SSE 14 SSE monitoring method Sets the method used for the SSE emergency ramp monitoring This parameter is relevant only if parameter SSE 13 SSE function is set to Emergency ramp Ramp Ramp Ramp monitoring SAR0 parameters define the eme...

Page 419: ...the motor actual speed reaches 0 rpm 30 000 ms 0 30 000 ms Time SSE 21 SSE output Sets the digital output that indicates the activity of the SSE function Active from the SSE request until the function has been acknowledged None None No output connected DO X113 7 X114 7 Redundant output X113 7 X114 7 DO X113 8 X114 8 Redundant output X113 8 X114 8 DO X113 9 X114 9 Redundant output X113 9 X114 9 DO ...

Page 420: ... X113 3 X114 3 DI X113 4 X114 4 Redundant input X113 4 X114 4 DI X113 1 Single input X113 1 DI X113 2 Single input X113 2 DI X113 3 Single input X113 3 DI X113 4 Single input X113 4 DI X114 1 Single input X114 1 DI X114 2 Single input X114 2 DI X114 3 Single input X114 3 DI X114 4 Single input X114 4 SS1 12 SS1 input B Sets the digital input that is connected to the secondary input of the SS1 func...

Page 421: ... Time SS1 15 SS1 r ramp zero speed delay for STO Sets an extra delay time for the drive STO and SBC if used activation at the zero speed limit in the SS1 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 The delay counter starts when the motor speed reaches the zero speed li...

Page 422: ...nt output X113 9 X114 9 DO X113 7 Single output X113 7 DO X113 8 Single output X113 8 DO X113 9 Single output X113 9 DO X114 7 Single output X114 7 DO X114 8 Single output X114 8 DO X114 9 Single output X114 9 41 SLSx Parameters for the SLS1 4 functions SLSx 02 SLS acknowledgement Sets the acknowledgement method used in the SLS1 4 functions Manual Manual The FSO module reads the external SLS ackno...

Page 423: ... 13 or 23 15 defines the deceleration ramp and it is monitored with parameter SLSx 04 SLS time delay SLSx 04 SLS time delay Sets the latest activation time for SLS monitoring after an SLS request This parameter is relevant only if time monitoring is used See parameter SLSx 03 SLS activation monitoring method Note With time monitoring when Monitoring active and Modoff delay time are selected SLSx 0...

Page 424: ...e STO SLS indication eg SLSx 15 goes on after STO 14 time has elapsed SLSx 06 SLS ramp modoff delay time Time to trip when modulation is lost Note This time must be set shorter than STO 14 otherwise STO is not activated due to limit hit when drive modulation is lost with SLS function Note If encoder feedback is in use SLSx 06 parameter has no effect 0 ms 0 3 600 000 ms Time SLSx 11 SLS1 input A Se...

Page 425: ... X114 4 Single input X114 4 SLSx 13 SLS1 trip limit negative Sets the SLS1 negative speed limit that trips the drive 0 0 rpm 35880 0 0 0 rpm Speed SLSx 14 SLS1 trip limit positive Sets the SLS1 positive speed limit that trips the drive 0 0 rpm 0 0 35880 0 rpm Speed SLSx 15 SLS1 output A Sets the primary digital output for the SLS1 function Active when SLS1 function is active and the motor speed is...

Page 426: ... Single output X114 9 SLSx 17 Mute time for SLS1 Sets the SLS1 specific mute time for limit hit situations This parameter is effective only with the safe speed estimate 0 ms 0 10000 ms SLSx 21 SLS2 input Sets the digital input for the SLS2 function None None No input connected DI X113 1 X114 1 Redundant input X113 1 X114 1 DI X113 2 X114 2 Redundant input X113 2 X114 2 DI X113 3 X114 3 Redundant i...

Page 427: ... specific mute time for limit hit situations This parameter is effective only with the safe speed estimate 0 ms 0 10000 ms SLSx 31 SLS3 input Sets the digital input for the SLS3 function None None No input connected DI X113 1 X114 1 Redundant input X113 1 X114 1 DI X113 2 X114 2 Redundant input X113 2 X114 2 DI X113 3 X114 3 Redundant input X113 3 X114 3 DI X113 4 X114 4 Redundant input X113 4 X11...

Page 428: ... is effective only with the safe speed estimate 0 ms 0 10000 ms SLSx 41 SLS4 input Sets the digital input for the SLS4 function None None No input connected DI X113 1 X114 1 Redundant input X113 1 X114 1 DI X113 2 X114 2 Redundant input X113 2 X114 2 DI X113 3 X114 3 Redundant input X113 3 X114 3 DI X113 4 X114 4 Redundant input X113 4 X114 4 DI X113 1 Single input X113 1 DI X113 2 Single input X1...

Page 429: ...X113 9 DO X114 7 Single output X114 7 DO X114 8 Single output X114 8 DO X114 9 Single output X114 9 SLSx 47 Mute time for SLS4 Sets the SLS4 specific mute time for limit hit situations This parameter is effective only with the safe speed estimate 0 ms 0 10000 ms SLSx 51 Variable SLS output Sets the digital output for the Variable SLS function Active when Variable SLS function is active and the mot...

Page 430: ...ARx ramps SARx 02 SAR initial allowed range Sets the initial allowed range for the SARx ramp This parameter moves the location of the maximum monitoring ramp forward on the time axis when monitoring is started The slope of the ramp stays the same as defined with parameters 200 202 and SARx 12 SAR0 or SARx 22 SAR1 For more information see section Ramp monitoring on page 57 0 ms 0 60 000 ms Time SAR...

Page 431: ...p monitoring SAR1 parameters define the deceleration ramp and monitoring limits See parameters 200 112 SARx 21 SARx 22 and SARx 02 Time Time monitoring The drive parameter 23 13 or 23 15 defines the deceleration ramp and it is monitored with parameter SDI 12 SDI delay SDI 12 SDI delay Sets the delay for starting SDI monitoring This parameter is relevant only when parameter SDI 10 SDI activation mo...

Page 432: ...A Sets the digital input connected to the SDI primary input for positive rotation None None No input connected DI X113 1 X114 1 Redundant input X113 1 X114 1 DI X113 2 X114 2 Redundant input X113 2 X114 2 DI X113 3 X114 3 Redundant input X113 3 X114 3 DI X113 4 X114 4 Redundant input X113 4 X114 4 DI X113 1 Single input X113 1 DI X113 2 Single input X113 2 DI X113 3 Single input X113 3 DI X113 4 S...

Page 433: ...4 9 Redundant output X113 9 X114 9 DO X113 7 Single output X113 7 DO X113 8 Single output X113 8 DO X113 9 Single output X113 9 DO X114 7 Single output X114 7 DO X114 8 Single output X114 8 DO X114 9 Single output X114 9 SDI 24 SDI positive output B Sets the digital output that is connected to the secondary output of the SDI positive function Active when the motor rotates in the correct positive d...

Page 434: ...nected to the SDI secondary input for negative rotation The secondary output is mostly used for cascade connection See parameters SAFEIO 12 Cascade A and SAFEIO 13 Cascade B None None No input connected DI X113 1 X114 1 Redundant input X113 1 X114 1 DI X113 2 X114 2 Redundant input X113 2 X114 2 DI X113 3 X114 3 Redundant input X113 3 X114 3 DI X113 4 X114 4 Redundant input X113 4 X114 4 DI X113 1...

Page 435: ...DO X113 9 X114 9 Redundant output X113 9 X114 9 DO X113 7 Single output X113 7 DO X113 8 Single output X113 8 DO X113 9 Single output X113 9 DO X114 7 Single output X114 7 DO X114 8 Single output X114 8 DO X114 9 Single output X114 9 41 SSMx Parameters for the SSM1 4 functions SSMx 01 SSM1 activity and version Activates or deactivates the SSM1 function and shows the version of the SSM1 function Di...

Page 436: ... input X114 3 DI X114 4 Single input X114 4 Always on The SSM1 function is always on SSMx 12 SSM1 limit negative Sets the negative speed limit for the SSM1 function 0 0 rpm 35880 0 0 0 rpm Speed SSMx 13 SSM1 limit positive Sets the positive speed limit for the SSM1 function 0 0 rpm 0 0 35880 0 rpm Speed SSMx 14 SSM1 output Sets the digital output connected to the SSM1 function Active when the moto...

Page 437: ...tion 0 0 rpm 0 0 35880 0 rpm Speed SSMx 24 SSM2 output Sets the digital output connected to the SSM2 function Active when the motor speed is within the SSM2 speed limits None None No output connected DO X113 7 X114 7 Redundant output X113 7 X114 7 DO X113 8 X114 8 Redundant output X113 8 X114 8 DO X113 9 X114 9 Redundant output X113 9 X114 9 DO X113 7 Single output X113 7 DO X113 8 Single output X...

Page 438: ...114 7 Redundant output X113 7 X114 7 DO X113 8 X114 8 Redundant output X113 8 X114 8 DO X113 9 X114 9 Redundant output X113 9 X114 9 DO X113 7 Single output X113 7 DO X113 8 Single output X113 8 DO X113 9 Single output X113 9 DO X114 7 Single output X114 7 DO X114 8 Single output X114 8 DO X114 9 Single output X114 9 SSMx 41 SSM4 input Sets the digital input connected to the SSM4 function None Non...

Page 439: ...113 9 Single output X113 9 DO X114 7 Single output X114 7 DO X114 8 Single output X114 8 DO X114 9 Single output X114 9 41 S_ENCGEN General parameters for safety pulse encoders S_ENCGEN 01 Safe pulse encoder version Activates or deactivates the safety encoder and shows the version of parameter group S_ENCGEN and parameters FSOGEN 52 and SBC 14 Disabled Disabled Deactivates the safety pulse encoder...

Page 440: ... the speed information from channel A and B of the encoder can be If the difference between these two values is greater than the value set to this parameter FSO will safely stop the system STO The suitable value depends on the configuration motor load Typically this value is set to 2 10 rpm a very low value will cause an encoder fault A7D8 whereas too high a value will prevent encoder diagnostic r...

Page 441: ...used 92 17 Accepted pulse freq of encoder 1 Sets the maximum pulse frequency of encoder 1 see Configuring the safety encoder interface on page 313 If the measured pulse frequency of the safety encoder is higher than the value set here the FSO module reaction depends on the S_ENCGEN 11 selection 0 0 kHz 0 300 kHz Frequency 41 SAFEIO Parameters for FSO inputs and outputs SAFEIO 11 M F mode for casca...

Page 442: ...cascade X114 1 X114 7 X114 2 X114 8 Single cascade X114 2 X114 8 X114 3 X114 9 Single cascade X114 3 X114 9 SAFEIO 13 Cascade B Sets the cascade connection B for the FSO module For each FSO module in cascade B the digital input connected to the safety function is also internally connected to the corresponding digital output of the FSO module digital input digital output See section Cascade on page...

Page 443: ...feedback input of safety relay 1 Parameter SAFEIO 23 Safety relay 1 feedback type sets the type of the feedback input None None No input connected DI X113 1 Single input X113 1 DI X113 2 Single input X113 2 DI X113 3 Single input X113 3 DI X113 4 Single input X113 4 DI X114 1 Single input X114 1 DI X114 2 Single input X114 2 DI X114 3 Single input X114 3 DI X114 4 Single input X114 4 SAFEIO 23 Saf...

Page 444: ...nput X114 1 DI X114 2 Single input X114 2 DI X114 3 Single input X114 3 DI X114 4 Single input X114 4 SAFEIO 26 Safety relay 2 feedback type Sets the type of the feedback signal for safety relay 2 Note The feedback delay is 800 ms for both feedback types that is a feedback signal from the safety relay must be received within 800 ms Mechanicall y linked NC contacts Mechanically linked NC contacts F...

Page 445: ...ff Diagnostic pulse off On Diagnostic pulse on SAFEIO 38 DI X114 2 diag pulse on off Sets the diagnostic pulse of digital input X114 2 on or off On Off Diagnostic pulse off On Diagnostic pulse on SAFEIO 39 DI X114 3 diag pulse on off Sets the diagnostic pulse of digital input X114 3 on or off On Off Diagnostic pulse off On Diagnostic pulse on SAFEIO 40 DI X114 4 diag pulse on off Sets the diagnost...

Page 446: ...ut X114 9 on or off On Off Diagnostic pulse off On Diagnostic pulse on SAFEIO 71 DO X113 7 logic state Sets the logic state of digital output X113 7 Active low Active low Active state of the output is low voltage Active high Active state of the output is high voltage SAFEIO 72 DO X113 8 logic state Sets the logic state of digital output X113 8 Active low Active low Active state of the output is lo...

Page 447: ... safety fieldbus equals to one full shaft revolution Note This parameter is relevant only when an encoder is used 1 0 0 01 30000 0 SBUSGEN 10 STO indication passivation Sets the type of the event that the FSO module generates when the FSO module is passivated due to safety fieldbus problems Fault None No event generated Fault Fault generated Warning Warning generated Event Pure event generated 41 ...

Page 448: ... PROFIsafe telegram 0x222 546 Corresponds to profile ABB_PS2 in the GSD file See section Downloading the GSD file on page 231 Note This profile requires that an encoder is used Index Name Value Description Factory default ...

Page 449: ...FbEq16 1 1 rpm FbEq32 100 1 rpm 200 02 FSO speed ch2 Shows the motor speed estimate 2 of the FSO module The FSO module reads the source data from the drive via communication channel 2 and calculates the speed estimate 2 using the data When safety encoder is used with FSE 31 module this parameter shows the speed measured with the safety encoder Note For a DCS880 drive the value of this parameter is...

Page 450: ... X114 9 0 Off 1 On 7 15 Reserved Bit Name Values 0 STO request 0 Off 1 On 1 SSE request 0 Off 1 On 2 SS1 request 0 Off 1 On 3 Reserved 4 SAR0 request 0 Off 1 On 5 SAR1 request 0 Off 1 On 6 Reserved 7 Reserved 8 Reserved 9 Reserved 10 SLS1 request 0 Off 1 On 11 SLS2 request 0 Off 1 On 12 SLS3 request 0 Off 1 On 13 SLS4 request 0 Off 1 On 14 Reserved 15 SDI positive request 0 Off 1 On Bit Name Value...

Page 451: ... safe mode 4 Configuration mode 1 FSO mode bit 2 2 FSO mode bit 3 3 FSO state bit 1 0 Safe state 1 Operational state 4 FSO state bit 2 5 FSO STO active 0 Off 1 On 6 Brake state 0 Off 1 On 7 POUS monitoring 0 Off 1 On 8 SSE monitoring 0 Off 1 On 9 SS1 monitoring 0 Off 1 On 10 Reserved 11 SAR0 monitoring 0 Off 1 On 12 SAR1 monitoring 0 Off 1 On 13 Reserved 14 Reserved 15 Reserved ...

Page 452: ...ve monitoring active and rotation direction correct 0 Off 1 On 7 SDI negative monitoring active and rotation direction correct 0 Off 1 On 8 SSM1 monitoring active and speed within limits 0 Off 1 On 9 SSM2 monitoring active and speed within limits 0 Off 1 On 10 SSM3 monitoring active and speed within limits 0 Off 1 On 11 SSM4 monitoring active and speed within limits 0 Off 1 On 12 SMS monitoring 0 ...

Page 453: ...ive status bit 2 2 Drive status bit 3 3 Drive status bit 4 4 Reserved 5 Encoder present An encoder is present 0 Off 1 On 6 Modulation Drive modulation on or off 0 Off 1 On 7 STO circuit 1 State of drive STO circuit 1 0 Off 1 On 8 STO circuit 2 State of drive STO circuit 2 0 Off 1 On 9 SS1 active State on the drive side 0 Off 1 On 10 Reserved 11 SAR0 active 0 Off 1 On 12 SAR1 active 0 Off 1 On 13 R...

Page 454: ...n the drive side 0 Off 1 On 2 SLS2 active 0 Off 1 On 3 SLS3 active 0 Off 1 On 4 SLS4 active 0 Off 1 On 5 Reserved 6 SDI positive active 0 Off 1 On 7 SDI negative active 0 Off 1 On 8 Drive brake state State of the drive operational brake 0 Off 1 On 9 STO 1 diag The drive has noticed an STO diagnos tic pulse on cir cuit 1 or 2 0 1 10 STO 2 diag 0 1 11 15 Reserved ...

Page 455: ...ropriate knowledge on functional machine and process safety The safety instructions must be followed during the start up See the drive and the safety component specific safety instructions in the individual product manuals WARNING Until all the safety functionality is validated the system must not be considered safe Note The safety of the machine users must be ensured in each phase of the applicat...

Page 456: ...he checklists provided in this document see chapter Installation checklists all necessary configuration steps have been completed all tools are cleared from the installation area to prevent short circuits and projectiles starting the system does not cause any danger all safety functions which are configured into use are validated according to chapter Verification and validation on page 457 ...

Page 457: ... for the system in the safety requirements specification phase The most convenient way to verify the required SIL PL level reached with the implemented system is to use a specific safety calculator software Purpose of the validation testing The purpose of the validation testing is to verify that the safety functions which are used in the safety system operate as required in the application and tha...

Page 458: ...ty functions has been appropriately verified and validated It is necessary to validate first the general settings of the FSO module and the safety encoder if in use before the validation of the safety functions Always configure and validate the STO and SSE functions An internal monitoring of the FSO module can trigger the STO or SSE function even if you have not defined an external request signal ...

Page 459: ... safety functions that are used in the safety application a list of all safety related parameters and their values the drive STO has no safety related parameters but listing the non safety related parameter 31 22 STO indication run stop and its setting is recommended documentation of start up activities references to failure reports and resolution of failures the test results for each safety funct...

Page 460: ...FINET profiles parameter 51 21 or 54 21 must be set to Enabled 0 to enable sending of the PROFIsafe diagnosis messages 5 Make sure that the PROFIsafe watchdog time for the fieldbus module that is configured in the controller station is calculated as specified in section Calculating the watchdog time on page 227 6 Make sure that the PROFIsafe address F_Dest_Add of the FSO module is unique in the ne...

Page 461: ...encoder If an encoder or FSE module failure occurs the reaction depends on the value of parameter S_ENCGEN 11 FSE diagnostic failure reaction STO No STO or Est switch not active load Validation procedure 1 Make sure that the correct installation instructions are followed when installing the safety encoder see the FSE module manual and the encoder manual 2 Make sure that safety encoder is configure...

Page 462: ... of the drive and FSO module 11 Make sure that the encoder rotation direction is correct See the parameters in the previous step If it is not correct exchange one differential pair in the cabling If you have configured S_ENCGEN 11 FSE diagnostic failure reaction to be STO or No STO follow the steps below 12 Make sure that system is safe for the coast stop test follows 13 a If you have configured F...

Page 463: ...ly If you have configured FSE diagnostic failure reaction S_ENCGEN 11 to be Est switch not active load follow the steps below to validate the safety encoder interface 12 Make sure that you can run and stop the motor freely 13 Start the drive to the motor speed typical for the application 14 Cause an encoder failure by disconnecting the one encoder signal channel wire from the FSE module 15 Make su...

Page 464: ...t 5 Document the test results to the validation test report 6 Sign and file the validation test report Validation of redundant inputs If safety function is configured to use redundant inputs the diagnostic function of each redundant input must be verified This is an validation example with the SS1 function Inputs X113 1 and X114 1 are set for the SS1 input Validation procedure 1 Remove one channel...

Page 465: ...general settings Make sure that the general settings of the safety functions are configured correctly according to your design For a configuration example see section Configuring general settings on page 312 Check the values of these parameters FSOGEN 41 Power up acknowledgement FSOGEN 42 Acknowledgement button input FSOGEN 22 Motor nominal frequency FSOGEN 21 Motor nominal speed FSOGEN 51 Zero sp...

Page 466: ...r is not used it must be ensured by other means for example by a visual check that the motor shaft stops within the STO 14 delay time and that the STO function cannot be acknowledged before the motor shaft has stopped The only exception to this is when STO 13 Restart delay after STO has been set shorter than STO 14 delay time In that case the fly start of the motor is possible To validate the STO ...

Page 467: ... that STO output STO 21 shows the state of the drive STO correctly 10 a If manual acknowledgement or safebus acknowledgement is in use Verify by trying to acknowledge the function that it is not possible before the motor speed is low enough With safe speed estimation Acknowledgement is not possible before coast time defined by parameter STO 14 Time to zero speed with STO and modoff If fly start is...

Page 468: ...BC output SBC 22 SBC feedback action SAFEIO 22 Safety relay 1 feedback SAFEIO 23 Safety relay 1 feedback type 3 Check that the drive STO and the SBC are activated correctly based on your application needs a When positive STO SBC delay SBC 12 is used Check that the drive STO is activated first and the SBC after the delay has elapsed Note When an encoder is used If the zero speed limit FSOGEN 52 is ...

Page 469: ...S1 SBC speed 0 rpm SBC 21 SBC output SBC 22 SBC feedback action SAFEIO 22 Safety relay 1 feedback SAFEIO 23 Safety relay 1 feedback type 3 Check that the drive STO and the SBC are activated correctly based on your application needs 4 Check that the brake is activated at the correct speed a When SBC 12 STO SBC delay is 0 ms or greater check that the SBC and drive STO is activated at the same time a...

Page 470: ...iggers the SSE Validation of the SSE with immediate STO function with safe speed estimation 1 Make sure that the input for the SSE function is configured according to the wiring diagram 2 Make sure that the SSE function is configured correctly according to your design For a configuration example see chapter How to configure SSE with immediate STO on page 351 Check these settings Activation SSE 11 ...

Page 471: ...ccording to the wiring diagram 2 Make sure that the SSE function and SAR0 setting or time monitoring limit is configured correctly according to your design For a configuration example see section How to configure SSE with time monitoring on page 354 or How to configure SSE with ramp monitoring on page 355 Check these settings Activation SSE 11 SSE input A SSE 12 SSE input B Note activation can als...

Page 472: ...FSOGEN 51 Zero speed without encoder With safety encoder FSOGEN 52 Zero speed with encoder b If automatic acknowledgement is in use Verify that the function is not acknowledged before the motor is in safe state see the conditions above 8 Make sure that the motor speed decelerates as expected and the FSO does not trip to the monitoring limit ramp or time 9 Start the drive and accelerate the motor t...

Page 473: ...ent STO 02 STO acknowledgement FSOGEN 42 Acknowledgement button input if manual acknowledgement is used Functionality SS1 01 SS1 activity and version Version 1 SS1 15 SS1 r ramp zero speed delay for STO if used 200 202 SAR speed scaling 200 112 SAR1 ramp time to zero drive parameter 23 23 emergency stop time if 200 112 0 ms if with safe speed estimation FSOGEN 51 Zero speed without encoder if with...

Page 474: ...encoder With safety encoder FSOGEN 52 Zero speed with encoder OR b If automatic acknowledgement is in use Verify that the function is not acknowledged before the motor speed is low enough See the conditions above 8 Make sure that the motor speed decelerates as it is designed and the FSO module does not trip to the monitoring limit ramp or time 9 After the motor is in safe state and the function is...

Page 475: ...gn For a configuration example see section Configuring SLS on page 362 Check these settings Activation 200 21 SLS1 activity and version SLSx 11 SLS1 input A SLSx 12 SLS1 input B only for SLS1 Functionality for the SLS function 200 22 SLS1 limit negative 200 23 SLS1 limit positive SLSx 13 SLS1 trip limit negative SLSx 14 SLS1 trip limit positive Acknowledgement SLSx 02 SLS acknowledgement FSOGEN 42...

Page 476: ...igher than the SLS limit Make sure that the drive does not follow speed references that are higher than the SLS limit 5 Make sure that the SLS indication output SLSx 15 or SLSx 16 indicates safe speed when motor speed is within SLS limits 6 Deactivate the SLS function Make sure that the SLS indication SLSx 15 or SLSx 16 goes off and the drive runs the motor according to the given user reference ou...

Page 477: ...n Functionality for the SLS function 200 52 SLS4 limit negative 200 53 SLS4 limit positive SLSx 42 SLS4 trip limit negative SLSx 43 SLS4 trip limit positive Acknowledgement SLSx 02 SLS acknowledgement FSOGEN 42 Acknowledgement button input if manual acknowledgement is used Functionality for the deceleration ramp a with ramp monitoring SLSx 03 SLS activation monitoring method Ramp 200 202 SAR speed...

Page 478: ...g values 8 Make sure that the deceleration ramp operates as required and no tripping fault occurs during the deceleration and that the reference SLS4 limits 100 scaling are set according to the application requirements 9 Make sure that SLSx 51 Variable SLS output indicates safe speed when motor speed is within the scaled variable SLS limits 10 Deactivate variable SLS function Make sure that the va...

Page 479: ...t in practice 2 Make sure that you can run and stop the motor freely 3 Start the drive and accelerate to a speed higher than SMS 14 SMS trip limit positive 4 Makes sure that the FSO module detects the over speed and activates the SSE function 5 Make sure that the SSE is configured according to the application safety requirements 6 Make sure that the acknowledgement of the SSE function is only poss...

Page 480: ...the motor speed to the required limit by the application Try to give a speed reference higher than the limit Make sure that the drive does not follow speed reference if it is higher than the SMS limit Repeat the test for both SMS limits if in use in the application 5 Make sure that also SMS trip limits 200 72 200 73 are set according to the application requirements This procedure does not test the...

Page 481: ...d Functionality POUS 13 POUS delay for completion Indication POUS 21 POUS output POUS 22 POUS completed output 6 Make sure that the motor is stopped 7 Activate the POUS function 8 Make sure that you cannot start the drive 9 Make sure that POUS output POUS 21 activates immediately when POUS function is requested according to the system design 10 Make sure that the POUS indication lamp goes on accor...

Page 482: ...version SSMx 11 SSM1 input Note Activation can also come from the PROFIsafe Functionality SSMx 13 SSM1 limit positive SSMx 12 SSM1 limit negative Indication SSMx 14 SSM1 output 3 Make sure that you can run and stop the motor freely 4 Start the drive and accelerate the motor to a higher speed than the speed defined by SSMx 13 SSM1 limit positive 5 Activate the SSM1 monitoring 6 Check that the statu...

Page 483: ...ion SDI 21 SDI positive input A SDI 22 SDI positive input B SDI 31 SDI negative input A SDI 32 SDI negative input B Note The activation can also come from the PROFIsafe Functionality for SDI function SDI 14 SDI tolerance limit degree SDI 02 SDI positive activity SDI 03 SDI negative activity Acknowledgement SDI 13 SDI acknowledgement FSOGEN 42 Acknowledgement button input if the manual acknowledgem...

Page 484: ...ction to the positive direction as described below Otherwise do the validation test to the other direction by replacing all directions below to opposite values in the procedure 1 Run motor to the positive direction 2 Activate SDI function to positive direction 3 Make sure that the SDI positive indication SDI 23 activates 4 Stop the motor or give 0 rpm user reference and make sure that the motor sh...

Page 485: ...485 11 Make sure that you can run the motor only into the correct negative direction 12 Deactivate the SDI negative request Repeat the same procedure for reverse SDI direction if it possible and if it is in use in your application ...

Page 486: ...heck these settings Master FSO SAFEIO 11 M F mode for cascade SAFEIO 12 Cascade A STO 02 STO acknowledgement automatic SSE 11 SSE input A SSE 12 SSE input B SSE 21 SSE output FSOGEN 42 Acknowledgement button input Follower FSO modules check the settings in each follower FSO module in the cascade chain SAFEIO 11 M F mode for cascade STO 02 STO acknowledgement Automatic SSE 11 SSE input A or SSE 12 ...

Page 487: ...en the proof test interval has elapsed the safety system has to be tested and restored to an as new condition The proof test must also be part of the regular maintenance plan For some of the components electronics the proof test interval is the same as the expected life time of the system A specific safety calculator software can assist in determining the requirements for the proof tests Residual ...

Page 488: ...488 Verification and validation ...

Page 489: ...s Each table is sorted by warning fault code Status LEDs The status LEDs are situated on the front of the FSO module The table below describes the status LED indications LED LED off LED lit and steady LED blinking POWER No power Green Power to the FSO is on RUN FSO is in the Fail safe mode and Safe state STO activated Green FSO is in the Operational or Safe state Green FSO is in the Configuration ...

Page 490: ...ame parameter also defines the event type that the FSO module generates when the function is completed Parameter FSOGEN 62 STO indication safety limit defines the event type for the limit hits of SLS1 SLS4 Variable SLS SMS and SDI functions ramp monitoring and time monitoring of the safety ramps SAR0 and SAR1 Parameter SBUSGEN 10 STO indication passivation defines the event type for the FSO module...

Page 491: ...nctions See section User selectable events for limit hits and special events on page 501 2 3 7A92 FSO out of eme ramp Motor speed was not inside the ramp window during the SSE function Make sure that the drive can decelerate the load using the ramp time 200 102 SAR0 ramp time to zero 2 7A93 FSO ramp coasted Drive coasted the motor to stop instead of using the ramp Check that the FSO module speed l...

Page 492: ...tool 3 A7D1 FSO internal fault Internal fault in the FSO module Reboot the FSO module If the problem still exits replace the FSO module Contact your local ABB representative 5 3 A7D2 FSO IO fault Problems in the I O cabling or safety relays Check the FSO I O cabling 4 3 A7D3 FSO STO fault Problems in the STO cabling or inside the drive Check the FSO STO cabling 4 A7D4 FSO STO request FSO module re...

Page 493: ...FSO module has completed the STO SS1 or SSE function 1 AA91 FSO safe speed limit FSO module detected an SLS or SMS speed trip limit violation Check the separate code related to SLS and SMS functions See section User selectable events for limit hits and special events on page 501 2 3 AA92 FSO out of eme ramp Motor speed was not inside the ramp window during the SSE function Make sure that the drive...

Page 494: ...rnal SSE request 1 AAA3 FSO SS1 request FSO module received an external SS1 request 1 AAA4 FSO SLS1 hit FSO module detected an SLS1 speed trip limit violation Investigate the reason for trip from the application point of view If application is OK then make sure that SLS is configured properly Make sure that SLS trip limits are defined properly Check that mute time values are defined properly FSOGE...

Page 495: ...FSO SMS hit FSO module detected an SMS speed trip limit violation Investigate the reason for trip from the application point of view If application is OK then make sure that SMS is configured properly Make sure that SMS trip limits are defined properly Check that mute time values are defined properly FSOGEN 31 or SMS 17 if enabled 2 6 AAA9 FSO SAR0 hit FSO module detected an SAR0 limit violation M...

Page 496: ...SS1 t delay for STO 2 AAB3 FSO zero spd hit Drive speed rushed during zero speed delay SSE 16 SSE ramp zero speed delay for STO or SS1 15 SS1 r ramp zero speed delay for STO Check the drive 2 AAB4 FSO speed sync fail FSO module detected a difference between the two monitored motor speed values 200 01 FSO speed ch1 and 200 02 FSO speed ch2 Restart the drive and FSO module 2 AAB5 FSO varSLS hit FSO ...

Page 497: ...p completed FSO module has completed the STO SS1 or SSE function 1 BA91 FSO safe speed limit FSO module detected an SLS or SMS speed trip limit violation Check the separate code related to SLS and SMS functions See section User selectable events for limit hits and special events on page 501 2 3 BA92 FSO out of eme ramp Motor speed was not inside the ramp window during the SSE function Make sure th...

Page 498: ...on is OK then make sure that SLS is configured properly Make sure that SLS trip limits are defined properly Check that transient mute time values are defined properly FSOGEN 31 or SLSx 17 if enabled and FSOGEN 33 2 6 BAA5 FSO SLS2 hit FSO module detected an SLS2 speed trip limit violation Investigate the reason for trip from the application point of view If application is OK then make sure that SL...

Page 499: ...roperly FSOGEN 31 or SMS 17 if enabled 2 6 BAA9 FSO SAR0 hit FSO module detected an SAR0 limit violation Make sure that the drive can decelerate the load using the ramp time 200 102 SAR0 ramp time to zero 2 BAAA FSO SAR1 hit FSO module detected an SAR1 limit violation Make sure that the drive can decelerate the load using the ramp time 200 112 SAR1 ramp time to zero 2 BAB0 FSO SDI positive hit SDI...

Page 500: ...ring of the FSO module exceeds the actual drive ramp time The parameter varies depending on the safety function For the SS1 function it is SS1 14 SS1 t delay for STO 2 BAB3 FSO zero spd hit Drive speed rushed during zero speed delay SSE 16 SSE ramp zero speed delay for STO or SS1 15 SS1 r ramp zero speed delay for STO Check the drive 2 BAB4 FSO speed sync fail FSO module detected a difference betw...

Page 501: ...ves a function request or detects that the function is completed User selectable events for limit hits and special events The table below lists user selectable events related to limit hits and special events Function Incident Events depending on the event type selection parameter FSOGEN 61 Fault Warning Event STO function STO request AAA1 FSO STO request warning 1 AAA1 FSO STO request BAA1 FSO STO...

Page 502: ...ning 1 AAB5 FSO varSLS hit BAB5 FSO varSLS hit System at safe state 7A91 FSO safe speed limit AA91 FSO safe speed limit BA91 FSO safe speed limit SMS SMS limit hit AAA8 FSO SMS hit warning 1 AAA8 FSO SMS hit BAA8 FSO SMS hit System at safe state 7A91 FSO safe speed limit AA91 FSO safe speed limit BA91 FSO safe speed limit SDI positive SDI positive hit AAB0 FSO SDI positive hit warning 1 AAB0 FSO S...

Page 503: ...fe state 7A92 FSO out of eme ramp AA92 FSO out of eme ramp BA92 FSO out of eme ramp Ramp time hit Ramp time hit AAB2 FSO ramp time hit warning 1 AAB2 FSO ramp time hit BAB2 FSO ramp time hit System at safe state 7A92 FSO out of eme ramp AA92 FSO out of eme ramp BA92 FSO out of eme ramp Zero speed hit Zero speed hit AAB3 FSO zero spd hit warning 1 AAB3 FSO zero spd hit BAB3 FSO zero spd hit System ...

Page 504: ...91 Resetting the drive is needed before resuming normal operation With fail safe state STO is activated and a relevant fault code is shown and in this case drive reset and FSO reboot are required before resuming normal operation If FSO enters the fail safe state because of external fault that can be repaired resuming to normal operation can take place after FSO reboot The steps for recovering from...

Page 505: ...To recover from these situations you may have to reboot the safety encoder for example by switching the power off and on If FSO is not recovering from the fault contact your local ABB representative Internal fault If there is an internal fault in FSO or FSE module that leads to a permanent defect the module must be replaced The FSO and FSE modules are not repairable Reporting problems and failures...

Page 506: ...506 Fault tracing ...

Page 507: ...he FSO module to factory settings how to recover the FSO module from fail safe mode information about updates to the safety system information about proof tests WARNING Obey the instructions in chapter Safety instructions If you ignore them injury or death or damage to the equipment can occur Planning All maintenance and repair actions on a safety critical system must be planned performed and docu...

Page 508: ...occur 1 Stop the driven machinery and prevent an unexpected start up 2 Upload the FSO parameters from the FSO to the Drive composer pro PC tool and save the safety file If this is not possible use a backup from a previous commissioning 3 Disconnect the supply with the supply disconnecting device For instructions on how to do this safely see the drive hardware manual Replacing the FSO module WARNIN...

Page 509: ...wer supply connector If the memory unit is installed back to the new control unit with existing drive firmware and parameter settings no other actions are necessary If a new memory unit is used the configuration must be read and restored with Drive composer pro 3 Do the start up and validation procedures See section Start up and validation test on page 510 Replacing the memory unit or updating the...

Page 510: ...lse encoder interface module user s manual 3AXD50000016597 English 3 Update the revision and the serial number of the new FSE module to the logbook of the driven machine Replacing the safety encoder 1 If the new encoder is not identical with the old encoder Make sure that the encoder meets the requirements in section Safety encoders on page 43 2 Install the new encoder according to the installatio...

Page 511: ...ath with for example a pen until the LEDs start to flash approximately 5 seconds This returns the factory settings parameters including the password to the FSO 3 Reconfigure the safety functions with the Drive composer pro PC tool To be able to restart the drive make sure that at least these parameters are set to suitable values according to your application 4 Set a new password with the tool Para...

Page 512: ...ication and validation Proof tests Periodic proof testing of the safety system may be required in order to maintain the claimed SIL PL level of the system to ensure that the safety integrity of a safety system is maintained continuously and does not deteriorate over time If proof testing is required it must be taken into consideration in the safety calculations maintenance manuals user documentati...

Page 513: ...dule make sure that the safety of the machine is maintained until the decommissioning is complete Mark clearly on the module that it is decommissioned If you use the SMS function version 2 obey the instructions in section SMS function version 2 on page 179 ...

Page 514: ...514 Maintenance ...

Page 515: ...y voltage 24 3 V DC SELV PELV Current consumption Maximum 1000 mA external power supply Inputs 4 redundant or 8 single or combinations of redundant and single 24 V DC NPN Maximum time delay between redundant input channels 300 ms Maximum test pulse tolerance 2 ms Outputs 3 redundant or 6 single or combinations of redundant and single 24 V DC PNP EMC Complies with EMC standards EN 61800 3 2004 and ...

Page 516: ...or size Tightening torque Solid or stranded Stranded ferrule without plastic sleeve Stranded ferrule with plastic sleeve Min Max Min Max Min Max Min Max Min Max Min Max mm2 AWG mm2 AWG mm2 AWG N m lbf in 0 14 1 5 26 16 0 25 1 5 23 16 0 25 0 5 23 21 0 24 2 1 Conductor size two conductors with the same cross section Tightening torque Solid Stranded Stranded ferrules without plastic sleeve Stranded T...

Page 517: ...n practices routing shielding supporting strain relief Data cable Use only the data cable included in the delivery Image No Description Torque 1 Grounding screw FSO module electronics 1 2 N m 10 6 lbf in Screws that attach mounting plate to FSO module 4 pcs On the back 0 96 N m 8 5 lbf in 3 Screws that ground the mounting plate to drive metal to metal 1 2 N m 10 6 lbf in OR Screws that attach the ...

Page 518: ... also be estimation ripples at the zero speed region below 2 Hz 3 of the nominal speed For more information see section Safe speed estimate on page 44 Operational frequency Drive output up to 598 Hz Operation installed for stationary use Storage in the protective package Transportation in the protective package Altitude 0 1000 m 0 3300 ft above sea level no derating required 1000 2000 m 3300 6600 ...

Page 519: ... Hz Constant deflection 7 mm 9 200 Hz Constant acceleration 20 m s2 Shock IEC 60068 2 27 Test Ea 2008 02 Peak acceleration 50 m s2 Pulse duration 30 ms 3 pulses in each direction with STO and SS1 functions activated Atmospheric pressure 70 106 kPa 0 7 1 05 atmospheres Stopping functions STO Safe torque off SBC Safe brake control SS1 Safe stop 1 SSE Safe stop emergency Speed related functions SLS S...

Page 520: ...n where FSO and drive are used is composed of the safety data of the subsystems Safety data for different subsystems is shown in section Basic safety data on page 522 Digital inputs and outputs Subsystems for the digital inputs and outputs of the FSO Can be used as single or dual channel and with or without diagnostic pulses Digital input STO output Digital output Speed measure ment Drive STO Swit...

Page 521: ...culations of those functions Drive STO is the actuator for the STO of the drive For the safety data see the drive hardware manual Note All safety functions except SSM have the capability to activate STO This means that STO subsystems STO output and Drive STO are always part of the safety function s calculations even though it might not be activated in normal use Speed measurement with FSE 31 is a ...

Page 522: ...ection Proof tests on page 512 EN IEC 61508 EN ISO 13849 1 EN IEC 62061 SIL up to 3 PL up to e SIL 3 3AXD10001287182 C 1 ch DI pulses 2 ch DI pulses 1 ch DI no pulses 2 ch DI no pulses Logic PROFI safe1 SIL 3 3 2 3 3 3 PL d e c e e e PFH 1 h T1 20 a 1 1E 10 5 5E 12 1 1E 08 2 9E 11 1 1E 11 1 0E 09 PFDavg T1 2 a 5 8E 08 5 9E 08 5 7E 06 6 7E 07 9 9E 08 8 8E 06 PFDavg T1 5 a 1 4E 07 1 5E 07 1 4E 05 1 ...

Page 523: ...tervals during operation on page 487 1 ch DO pulses 2 ch DO pulses 1 ch DO no pulses 2 ch DO no pulses STO output Speed estimate worst case values Speed measure ment with FSE 31 SIL 3 3 1 3 3 3 3 PL d e c e e e e PFH 1 h T1 20 a 6 3E 10 1 7E 10 4 9E 09 2 2E 10 1 8E 11 1 0E 08 6 4E 08 PFDavg T1 2 a 3 8E 07 1 5E 06 2 3E 06 2 4E 06 1 6E 07 1 4E 04 9 7E 05 PFDavg T1 5 a 9 6E 07 3 7E 06 5 7E 06 5 9E 06...

Page 524: ...on safety values In general if the safety function contains any 1 channel digital input or output of the FSO with non pulsed signals the subsystem Logic 1 must be used Block diagrams are equal to SS1 t SSE t and SSE with immediate STO functions Same approach for the logic subsystems applies in all safety functions below Note ABB s safety data component libraries do not contain any subsystems for e...

Page 525: ...ed speed SLS with encoder includes the following subsystems safety encoder not provided by ABB FSE 31 FSO Digital input FSO Logic 1 or 2 FSO STO output FSO Digital output optional and Drive STO Block diagram is equal to SDI and SS1 r 1 FSO encoderless speed measurement 2 FSO Digital input 3 FSO Logic 1 or 2 4 FSO STO output 5 FSO Digital output optional 6 Drive STO 1 Safety encoder input device 2 ...

Page 526: ...ptional and Drive STO SMS without encoder Safe maximum speed SMS includes the following subsystems FSO encoderless speed measurement FSO Logic 2 FSO STO output and Drive STO 1 FSO Digital input 2 FSO Logic 1 or 2 3 FSO STO output 4 FSO Digital output optional 5 Drive STO 1 FSO encoderless speed measurement 2 FSO Logic 2 3 FSO STO output 4 Drive STO 1 2 3 4 5 1 2 3 4 ...

Page 527: ...g subsystems FSO Logic 2 FSO STO output FSO Digital output Contactor 1 and 2 can be provided by ABB and Drive STO Note SBC is used together with other safety functions and a triggering subsystem must be included in the calculation 1 Safety encoder input device 2 FSE 31 3 FSO Logic 2 4 FSO STO output 5 Drive STO 1 FSO Logic 2 2 FSO STO output 3 FSO Digital output 4 Contactor 1 5 Contactor 2 6 Drive...

Page 528: ...r Safe speed monitor SSM with encoder includes the following subsystems safety encoder not provided by ABB FSE 31 FSO Digital input optional FSO Logic 1 or 2 and FSO Digital output Note This safety function SSM with encoder can be configured so that it is always active In this case digital input is not included in the safety calculation 1 FSO encoderless speed measurement 2 FSO Digital input optio...

Page 529: ...s PLC uses safe position information to operate a safety function In this case FSE 31 subsystem should be added in the calculation Safety data for some typical configurations The tables below show FSO 21 safety data for some safety functions with typical combinations of the FSO module subsystems See section Basic safety data on page 522 for more information on the subsystems Values without the FSE...

Page 530: ...ogic STO output Speed estimate 1 1E 08 1 5E 04 2 9E 04 5 9E 04 99 0 1 3 161 98 6 3 e 3AXD10001287182 C 1 Lowest subsystem SFF 2 Lowest subsystem DC Subsystems used in the safety function PFH 1 h PFDavg PFDavg PFDavg SFF1 HFT SIL MTTFD DC2 Cat PL T1 20 a T1 2 a T1 5 a T1 20 a a 1 channel pulsed DI Logic STO output 1 channel pulsed output Speed measurement 6 4E 08 9 8E 05 9 9E 04 96 8 0 2 1115 96 6 ...

Page 531: ...ependent of the other channel The relevant failure mode of the diagnostics is that due to a random hardware fault in the diagnostic system the fault reaction is not performed while a detectable fault in the safety function is present For FSO 21 with or without FSE 31 module there are no dangerous failures that are not detected by the diagnostics 2 channel pulsed DI Logic STO output 2 channel pulse...

Page 532: ...100 ms DCS880 drives Maximum response time is 550 ms Note Mute time usage increases the response time FSO 21 response time from an FSO input to an FSO digital output activation Maximum 35 ms Cascade response time from FSO s STO activation to the cascade output activation Maximum 35 ms from the cascade input to the cascade output activation Maximum 35 ms If the STO is cascaded safety function respo...

Page 533: ...request from I O or PROFIsafe PROFIsafe STO ack WCDT DO activation Removal of torque Drive 35 ms 54 ms 100 ms 0 ms 100 ms 35 54 Time STO request from I O or PROFIsafe Drive 1 DO activation for cascading Removal of torque Drive 1 35 ms STO request through cascading Drive 2 DO activation for cascading Drive 2 Removal of torque Drive 2 STO request from through cascading Drive 3 DO activation for casc...

Page 534: ...rdering codes for related kits Option codes plus codes when ordered together with drive FSO 21 kit 3AXD50000023987 FSE 31 kit 3AXD50000023272 FENA 21 3AUA0000089109 FPNO 21 3AXD50000192779 FSO 21 Q972 FSE 31 kit L521 FENA 21 K475 FPNO 21 K492 ...

Page 535: ...ntrol systems Part 1 General principles for design EN ISO 13849 2 2012 Safety of machinery Safety related parts of control systems Part 2 Validation IEC 61800 3 2004 A1 2011 Adjustable Speed Electrical Power Drive Systems Part 3 EMC requirements and specific test methods IEC 61000 6 7 2014 Electromagnetic compatibility EMC Part 6 7 Generic standards Immunity requirements for equipment intended to ...

Page 536: ...536 Technical data ...

Page 537: ...wings 537 17 Dimension drawings The dimension drawings of the FSO 21 module with two different bottom plates for different drive control unit types are shown below The dimensions are given in millimeters and inches ...

Page 538: ...538 Dimension drawings 3AXD50000018513 ...

Page 539: ...ce contacts can be found by navigating to abb com searchchannels Product training For information on ABB product training navigate to new abb com service training Providing feedback on ABB Drives 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...

Page 540: ...abb com Copyright 2022 ABB All rights reserved Specifications subject to change without notice 3AXD50000015614 Rev H EN 2022 01 07 ...

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