Maintenance; Proof Test Interval; Competence; Residual Risk - ABB ACS880-07 User Manual

Maintenance

After the operation of the safety function is tested at start-up, it does not need any
scheduled maintenance, excluding the main contactor which has a limited lifetime.
Replace the contactor before the end of its lifetime. See the contactor data sheet or
manual. Repeat the acceptance test for the function after the replacement. See section
Start-up and acceptance test
In addition to proof testing, it is a good practice to check the operation of the function when
other maintenance routines of the machinery are carried out. Do the acceptance test
described in section
If you change any wiring or component after the start up, or restore parameters to their
default values:
•
Use only ABB approved spare parts.
•
Register the change to the change log for the safety circuit.
•
Test the safety function again after the change. Obey the rules given in section
up and acceptance test
•
Document the tests and store the report into the logbook of the machine.

Proof test interval


After the operation of the safety function is validated at start-up, the safety function must
be maintained by periodic proof testing. In high demand mode of operation, the maximum
proof test interval is 20 years. In low demand mode of operation, the maximum proof test
interval is 1 year (high or low demand as defined in IEC 61508, EN/IEC 62061 and
EN ISO 13849-1). Regardless of the mode of operation, it is a good practice to check the
operation of the safety function at least once a year. Do the test as described in section
Start-up and acceptance test
The person responsible for the design of the complete safety function should also note the
Recommendation of Use CNB/M/11.050 published by the European co-ordination of
Notified Bodies for Machinery concerning dual-channel safety-related systems with
electromechanical outputs:
•
When the safety integrity requirement for the safety function is SIL 3 or PL e (cat. 3 or
4), the proof test for the function must be performed at least every month.
•
When the safety integrity requirement for the safety function is SIL 2 (HFT = 1) or PL d
(cat. 3), the proof test for the function must be performed at least every 12 months.
This is a recommendation and depends on the required (not achieved) SIL/PL. For
example, safety relays, contactor relays, emergency stop buttons, switches etc. are
typically safety devices which contain electromechanical outputs.

Competence


The maintenance and proof test activities of the safety function must be carried out by a
competent person with adequate expertise and knowledge of the safety function as well as
functional safety, as required by IEC 61508-1 clause 6.

Residual risk


The safety functions are used to reduce the recognized hazardous conditions. In spite of
this, it is not always possible to eliminate all potential hazards. Therefore the warnings for
the residual risks must be given to the operators.
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Start-up and acceptance test
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Option description and instructions 21
on page 18.
Start-