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ABB +Q951 User Manual Download Page 8

Instructions for functional safety circuits

This manual does not contain the complete safety instructions of the drive. It only includes
the instructions related to the scope of this manual.

Only a qualified electrical professional who has sufficient knowledge about functional,
machine, and process safety is permitted to install, start up and maintain the safety circuit.
All user-made changes are on the user's responsibility.

WARNING!

The safety functions described in this manual do not isolate the main circuit or
auxiliary circuit from the power supply. Do not do work on the drive, motor cable
or motor before you have isolated the drive system from all power supplies and
measured that there are no dangerous voltages. Before you start the work, do the
steps in section

Electrical safety precautions (page 9)

.

WARNING!

Do the validation test of the safety function at the start-up and also after you make
changes to the safety circuit.

WARNING!

Make 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.

WARNING!

Obey the safety instructions of the drive. If you ignore them, injury or death,
or damage to the equipment can occur. If you are not a qualified electrical
professional, do not do installation or maintenance work.

8 Safety instructions

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Summary of Contents for +Q951

Page 1: ... OPTIONS FOR ABB INDUSTRIAL DRIVES Emergency stop functions with button monitoring options Q951 Q984 and Q952 Q984 for ACS880 liquid cooled drives User s manual ...

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Page 3: ...ing options Q951 Q984 and Q952 Q984 for ACS880 liquid cooled drives User s manual Table of contents 1 Safety instructions 5 Electrical installation 7 Start up and validation test 3AXD50000328659 Rev B EN Original instructions EFFECTIVE 2020 12 28 ...

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Page 5: ...principle 16 ACS880 07CLC drives 18 ACS880 07LC drives 20 ACS880 17LC 37LC drives 22 ACS880 multidrives 23 Fault reaction function 24 Parameter settings 24 ACS880 07CLC 07LC 17LC 37LC drives 24 ACS880 multidrives 25 Hardware settings 25 ACS880 07CLC drives 25 ACS880 07LC 17LC 37LC drives and ACS880 multidrives 25 Push button monitoring relays 4 Description of option Q952 Q984 27 Contents of this c...

Page 6: ...ts 44 Validation test 8 Fault tracing 47 Contents of this chapter 47 General 47 Emergency stop safety relay 47 ACS880 07CLC drives with option Q951 Q984 48 ACS880 07LC 17LC 37LC drives and ACS880 multidrives with option Q951 Q984 48 ACS880 07LC 17LC 37LC drives and ACS880 multidrives with option Q952 Q984 49 Monitoring relays 9 Maintenance 51 Contents of this chapter 51 Safety circuit maintenance ...

Page 7: ...otes draw attention to a particular condition or fact or give information on a subject The manual uses these warning symbols WARNING Electricity warning tells about hazards from electricity which can cause injury or death or damage to the equipment WARNING General warning tells about conditions other than those caused by electricity which can cause injury or death or damage to the equipment WARNIN...

Page 8: ... motor before you have isolated the drive system from all power supplies and measured that there are no dangerous voltages Before you start the work do the steps in section Electrical safety precautions page 9 WARNING Do the validation test of the safety function at the start up and also after you make changes to the safety circuit WARNING Make sure that the functional safety of the machine is mai...

Page 9: ...bars of the drive cabinet If the drive is equipped with a DC DC converter unit optional Open the DC switch disconnector Q11 option F286 of the DC DC converter Open the disconnecting device of the energy storage connected to the DC DC converter unit outside the drive cabinet Open the auxiliary voltage switch disconnector if present and all other possible disconnecting devices that isolate the drive...

Page 10: ...etween the drive output terminals T1 U T2 V T3 W and the grounding PE busbar is zero Make sure that the voltage between the drive DC terminals UDC and UDC and the grounding PE terminal is zero In cabinet built drives measure between the drive DC busbars and and the grounding PE busbar WARNING The busbars inside the cabinet of liquid cooled drives are partially coated Measurements made through the ...

Page 11: ...ion Q952 Q984 Note The contents of this manual are applicable only to drives with push button monitoring option Q984 There are separate manuals for options Q951 and Q952 which are not applicable when combined with option Q984 This manual shows the default design of the safety circuit The actual design can be different from the default design because of customer defined modifications Always refer t...

Page 12: ...manual Do the validation test You can find instructions for the validation test in this manual Document the validation test procedure You can find the guidelines for the validation test report in this manual Related documents Code Name Drive hardware 3AXD50000131457 ACS880 07CLC drives hardware manual 3AXD50000569786 ACS880 07LC drives hardware manual 3AXD50000250295 ACS880 17LC drives hardware ma...

Page 13: ...s ACS880 07CLC manuals ACS880 37LC manuals Terms and abbreviations Description Term Control board built in a housing often rail mountable Control unit Frequency converter for controlling AC motors Drive Converts direct current and voltage to alternating current and voltage Inverter Inverter bridge related components and drive DC link capacitors enclosed in a metal frame or enclosure Intended for c...

Page 14: ...C 61508 IEC 62061 Proof test Safety integrity level 1 3 IEC 61508 SIL Safe torque off IEC EN 61800 5 2 STO Supply module s under control of one control unit and related components Supply unit Confirmation by for example analysis that the safety system meets the functional safety requirements of the specific application Validation Confirmation by for example testing that the safety system meets the...

Page 15: ... activates the emergency stop function when pushed Line faults in the primary safety circuit will cause the emergency stop function to activate the user implemented push button circuits which are connected to the push button monitoring relays The push buttons activate the emergency stop function when pushed but line faults in the push button circuits will not cause the emergency stop function to a...

Page 16: ...1B IN1 SGND IN2 SGND OUT1 SGND OUT2 SGND A640 A640 A51 DIIL 24 VDC A51 DIIL 24 VDC A640 A51 DIIL 24 VDC K640 K640 Q4 Q4 230 VAC K640 K640 Qx Qx 4 A641 1 BUS 3 1 3 2 A641 1 BUS 3 1 3 2 A640 S61 S61 S62 S62 A64x R1 R2 BUS 3 A64x R1 R2 BUS 3 S62 S62 Qx Qx 24 VDC 2 A642 R1 R2 BUS 3 A642 R1 R2 BUS 3 Qx T01 Q4 T11 M 3 M 3 T11 M 3 Qx T01 Q4 T11 M 3 Q4 Q4 6 User defined connection Inverter control unit A4...

Page 17: ...izes XSTO inputs IN1 and IN2 of the inverter control unit A41 This activates the inverter unit Safe torque off function 2 The emergency stop safety relay A640 de energizes the DIIL input on the supply control unit A51 This gives the emergency stop command to the supply unit The emergency stop safety relay A640 de energizes the safety relay K640 The safety relay K640 opens the main contactor breake...

Page 18: ...D IN2 SGND OUT1 SGND OUT2 SGND K62 2 X969 24 VDC Qx Qx K62 1 K62 1 5 User defined connection Inverter control unit A41 Supply control unit A51 Emergency stop safety relay A61 Main monitoring relay for the push buttons A641 Push button monitoring relays A642 A64X Safety relays K62 1 K62 2 Push button resistors R1 R2 Main contactor breaker Qx Emergency stop button S61 Emergency stop reset button wit...

Page 19: ...relay K62 2 de energizes the DIIL input on the supply control unit A51 This gives the emer gency stop command to the supply unit Safety relay K62 1 opens the main contactor breaker Qx which disconnects the input power from the supply unit T01 The emergency stop reset button indicator light S62 comes on 3 The motor coasts to a stop 4 Normal operation resumes after the user 5 releases the emergency ...

Page 20: ... IN1 SGND OUT OUT1 SGND OUT2 SGND X52B X51B IN1 SGND IN2 SGND OUT1 SGND OUT2 SGND A61 X969 24 VDC Q4 Q4 K62 2 K62 2 Qx Qx 5 User defined connection Inverter control unit A41 Supply control unit A51 Emergency stop safety relay A61 Main monitoring relay for the push buttons A641 Push button monitoring relays A642 A64X Safety relays K62 1 K62 2 Push button resistors R1 R2 Main contactor breaker Qx Ch...

Page 21: ... control unit A51 This gives the emergency stop command to the supply unit The emergency stop safety relay A61 de energizes safety relay K62 1 Safety relay K62 1 opens the main contactor breaker Qx which disconnects the input power from the supply unit T01 The charging contactor Q4 is opened if the emergency stop is activated during charging The emergency stop reset button indicator light S62 come...

Page 22: ... VDC S62 S62 S62 2 S61 Qx T01 Q4 T11 M 3 M 3 T11 M 3 TXX M 3 M 3 TXX M 3 Qx T01 Q4 T11 M 3 TXX M 3 Qx T01 Q4 T11 M 3 TXX M 3 K64 K64 Qx Qx Q4 Q4 Qx Qx K65 K65 230 VAC Q4 Q4 K64 Qx Q4 Qx K65 230 VAC Q4 A642 R1 R2 BUS 3 A642 R1 R2 BUS 3 A641 1 BUS 3 1 3 2 A641 1 BUS 3 1 3 2 A64x R1 R2 BUS 3 A64x R1 R2 BUS 3 6 User defined connection Inverter control unit A41 Supply control unit A51 Emergency stop sa...

Page 23: ...op is activated during charging The emergency stop reset button indicator light S62 comes on 3 The motors coast to a stop 4 Normal operation resumes after the user 5 releases the emergency stop button S61 or the user defined push button to normal up position pushes the emergency stop reset button S62 to reset the emergency stop circuit closes the main contactor breaker Qx makes sure that the inver...

Page 24: ... unit is running DIIL Emergency stop source 121 05 1 Value set by ABB at the factory for the default design ACS880 multidrives The parameter settings in the ACS880 primary control program Description Default value1 Name No Selects a drive signal to be connected to relay output RO1 In this case the source is the inverted value of parameter 10 01 DI status bit 3 DI4 P 10 1 3 2 RO1 source 10 24 Selec...

Page 25: ...de at the factory ACS880 07LC 17LC 37LC drives and ACS880 multidrives The settings in the emergency stop safety relay A61 are Cross fault detection is set to Without Start mode is set to Manual Push button monitoring relays The DIP switches of the push button monitoring relays are set at the factory as follows DIP switch Relay S4 S3 S2 S1 I II K641 I I II I K642 K64x Description of option Q951 Q98...

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Page 27: ...ctivates the emergency stop function when pushed Line faults in the primary safety circuit will cause the emergency stop function to activate the user implemented push button circuits which are connected to the push button monitoring relays The push buttons activate the emergency stop function when pushed but line faults in the push button circuits will not cause the emergency stop function to act...

Page 28: ... 2 DIIL 24 VDC A61 24 VDC K62 2 K62 2 S62 S62 S62 S62 K61 K61 A41 A412 X DIO1 DIO2 X65 1 2 X65 1 2 DIO1 DIO2 X65 1 2 K61 K61 T11 x XSTO XSTO OUT 4 IN2 OUT SGND IN1 IN2 OUT SGND IN1 OUT1 SGND OUT2 SNGD OUT1 SGND OUT2 SNGD X51B X52B IN1 SGND IN2 SGND IN1 SGND IN2 SGND OUT1 SGND OUT2 SGND OUT1 SGND OUT2 SGND X969 X969 K62 1 K62 1 K62 2 K62 2 K62 3 K62 3 K62 1 K62 1 S61 Qx Qx A641 1 BUS 3 1 3 2 A641 1...

Page 29: ...61 The break delay counter of the emergency stop safety relay A61 starts user adjustable delay The break delay counter of the timer relay K61 starts non user adjustable delay The inverter unit acknowledges the reception of the emergency stop command by energizing the relay output X65 of the digital I O extension module A412 X 3 The relay output X65 of the extension module A412 X energizes the time...

Page 30: ...24 VDC A61 24 VDC K62 2 K62 2 S62 S62 S62 S62 K61 K61 A41 A412 X DIO1 DIO2 X65 1 2 X65 1 2 DIO1 DIO2 X65 1 2 K61 K61 T11 x XSTO XSTO OUT 4 IN2 OUT SGND IN1 IN2 OUT SGND IN1 OUT1 SGND OUT2 SNGD OUT1 SGND OUT2 SNGD X51B X52B IN1 SGND IN2 SGND IN1 SGND IN2 SGND OUT1 SGND OUT2 SGND OUT1 SGND OUT2 SGND X969 X969 K62 1 K62 1 K62 2 K62 2 K62 3 K62 3 K62 3 K62 3 K62 1 K62 1 A61 A61 S61 Q4 Q4 Qx Qx A641 1 ...

Page 31: ...table delay The break delay counter of the timer relay K61 starts non user adjustable delay The inverter unit acknowledges the reception of the emergency stop command by energizing the relay output X65 of the digital I O extension module A412 X 3 The relay output X65 of the extension module A412 X energizes the timer relay K61 resetting its break delay counter The relay keeps its delayed break con...

Page 32: ... circuit diagrams delivered with the drive A61 T61 T61 T61 K66 K66 K65 K65 K66 K65 K61 K61 K63 K63 K61 K63 K63 DI4 A41 T11 x XSTO XSTO OUT 5 IN2 OUT SGND IN1 IN2 OUT SGND IN1 OUT1 SGND OUT2 SNGD OUT1 SGND OUT2 SNGD X51B X52B IN1 SGND IN2 SGND IN1 SGND IN2 SGND OUT1 SGND OUT2 SGND OUT1 SGND OUT2 SGND RO1 4 K61 K61 K61 F61 F61 4 A51 K66 K66 DIIL 24 VDC A51 K66 DIIL 24 VDC S62 K66 K66 K64 K64 2 S61 K...

Page 33: ...p safety relay A61 de energizes the digital input on the inverter unit control units A41 This gives the emergency stop command to the inverter units 2 The break delay counter of the emergency stop safety relay A61 starts user adjustable delay Each inverter unit acknowledges the reception of the emergency stop command by energizing the relay outputs RO1 on the inverter control units A41 3 The relay...

Page 34: ...not applicable to ACS880 multidrives opens the main contactor breaker keeps the safe state activated and the emergency stop reset button indicator light on until the fault is repaired and the safety function is reset Note Resetting the safety function is not possible if the reset circuit in the emergency stop safety relay is open If you hold the reset button S62 pushed for more than 10 seconds the...

Page 35: ...fines the zero speed limit The motor is stopped along a speed ramp until this limit is reached After the zero speed delay parameter 21 07 default value 0 ms the motor coasts to a stop User defined Zero speed lim it 21 06 Defines the deceleration time for emergency stop Off3 The deceleration time is the time it takes to decelerate the motor from the maximum process speed defined by parameter 46 01 ...

Page 36: ...ms the motor coasts to a stop User defined Zero speed lim it 21 06 Defines the deceleration time for emergency stop Off3 The deceleration time is the time it takes to decelerate the motor from the maximum process speed defined by parameter 46 01 or 46 02 to the zero speed limit defined by parameter 21 06 User defined Emergency stop time 23 23 Defines the maximum motor speed used in the application...

Page 37: ...s the delay mode Must be 1 1 tFkt Selects the time range in seconds for the delayed contacts User defined tmax Value range 1 300 s Adjusts the time within the selected range in 10 steps User defined t Value range 0 1 1 Multiply the values of tmax and t to get the time delay tv tmax t For example if the required time is 30 s you can set the switches as follows tmax 30 s t 1 30 s 1 30 s or tmax 300 ...

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Page 39: ...ne channel connection to the emergency stop safety relay A61 or A640 at the factory User made connections to this circuit are not necessary You must not install additional emergency stop buttons in series with the emergency stop button If the drive does not have a factory installed main contactor breaker you must install one and connect its control circuit and status monitoring circuit to the driv...

Page 40: ...he table that follows Resistance Resistor 1000 ohm R1 10000 ohm R2 Connecting the push button fault indication The main monitoring relay A641 has a normally closed relay contact that you can use to implement a fault indication system Installation procedure 1 Stop the drive and do the steps in section Electrical safety precautions page 9 before you start the work 2 Connect the relay contact to the ...

Page 41: ...locks in the ON open position ACS880 07CLC 07LC 17LC 37LC drives the inverter unit control program has the warning Safe torque off active ACS880 multidrives the inverter unit control program has the warning Emergency stop active the supply unit control program has the warning Emergency stop active the emergency stop reset button indicator light S62 on the cabinet door is on If configured with para...

Page 42: ...S62 on the cabinet door for 0 1 3 seconds The emergency stop reset button indicator light S62 goes off and the emergency stop is deactivated 3 If necessary reset faults from the drive 4 If necessary close the main contactor breaker 5 Make sure that the drive receives the start signal 6 You can now restart the drive For more information see the hardware and firmware manuals Note You must also reset...

Page 43: ...ge of the safety function and functional safety This person must document and sign the test procedures and report Validation procedure You must do the validation test using the checklist given in this manual at the initial start up of the safety function after changes related to the safety function wiring components safety function related parameter settings etc after maintenance work related to t...

Page 44: ...est Action WARNING Obey the safety instructions of the drive If you ignore them injury or death or damage to the equipment can occur Initial status Make sure that the drive is ready for use that is you have done the tasks of the drive start up procedure See the hardware manual Make sure that the STO function is configured and validated See the drive or inverter unit hardware manual Checks and sett...

Page 45: ...The motors coast to a stop ACS880 multidrives with option Q952 Q984 The drive decelerates the motors to a stop according to a user defined ramp Make sure that the drive shows the correct indications Make sure that the emergency stop reset button indicator light S62 comes on Make sure that the main contactor breaker Qx opens Make sure that the drive generates none of these faults STO hardware failu...

Page 46: ... Cause a line fault in the push button circuit for example disconnect a wire from the push button 2 Make sure that the fault indication from the main monitoring relay A641 is activated 3 Make sure that the emergency stop function is not activated Repeat this test for each push button circuit connected to the push button monitoring relays A642 A64x Create a backup file of the drive parameters with ...

Page 47: ...ilure 5090 Safe torque off 1 loss FA81 Safe torque off 2 loss FA82 For more information see the hardware and firmware manuals Emergency stop safety relay ACS880 07CLC drives with option Q951 Q984 The type of the emergency stop safety relay A640 is Phoenix Contact PSR MC34 This table gives the indications of the Phoenix Contact PSR MC34 relay State K2 LED K1 LED IN1 2 LED PWR LED All relays are not...

Page 48: ... is energized K2 For more information see the data sheet of the relay www dold com For more fault tracing possibilities see the hardware and firmware manuals of the drive ACS880 07LC 17LC 37LC drives and ACS880 multidrives with option Q952 Q984 The type of the emergency stop safety relay A61 is DOLD UG 6960 This table gives the indications of the DOLD UG 6960 relay LED is off LED is flashing LED i...

Page 49: ...ch it back on Monitoring relays The monitoring relay types are main monitoring relay A641 Phoenix Contact MCR PTB SP push button monitoring relays A642 A64x Phoenix Contact MCR SL NAM R SP This table gives the indications of the Phoenix Contact MCR PTB SP relay Status indication Color LED Supply voltage Green PWR 1 Supply voltage Green PWR 2 Error Red ERR This table gives the indications of the MC...

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Page 51: ...r the safety circuit If parameters were restored to the factory default values Set the parameters related to the safety function Do the validation test of the safety function Document the tests and store the report into the logbook of the machine Proof test To do a proof test activate the safety function to make sure that it operates correctly For guidelines refer to the validation test procedure ...

Page 52: ...er restarting their mission time The remaining mission time of the whole circuit is however determined by its oldest component Contact your local ABB service representative for more information Competence The person who does the maintenance and proof test activities of the safety function must be a competent person with expertise and knowledge of the safety function and functional safety Residual ...

Page 53: ...nts are as follows push button monitoring relays A642 A64x 10 years other components 20 years The mission time of the safety function is equal to the lowest mission time of the safety circuit components Thus for the safety functions shown in this manual the mission time is 10 years Ambient conditions For the environmental limits for the safety functions and the drive refer to the drive hardware ma...

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Page 55: ... by navigating to www abb com searchchannels Product training For information on ABB product training navigate to new abb com service training Providing feedback on ABB manuals Your comments on our manuals are welcome Navigate to new abb com drives manuals feedback form Document library on the Internet You can find manuals and other product documents in PDF format on the Internet at www abb com dr...

Page 56: ...www abb com drives 3AXD50000328659B Copyright 2020 ABB All rights reserved Specifications subject to change without notice 3AXD50000328659 Rev B EN EFFECTIVE 2020 12 28 ...

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