ABB FSO-12 Manuals

ABB FSO-12 Manuals

Manuals and User Guides for ABB FSO-12. We have 2 ABB FSO-12 manuals available for free PDF download: User Manual

ABB FSO-12 User Manual

ABB FSO-12 User Manual (426 pages)

safety functions module

Brand: ABB | Category: Control Unit | Size: 12 MB

Table of Contents

List of Related Manuals
2
Table of Contents
5
Safety Instructions
13
Contents of this Chapter
13
Use of Warnings
13
Electrical Safety Precautions
14
Introduction to the Manual
17
Contents of this Chapter
17
Exclusion of Liability
17
Applicability
17
Compatible Products
18
ACS880 Drives and Option Modules
18
Controller Stations
20
Tools
20
Supported Safety Functions
21
Target Audience
21
Purpose of the Manual
21
Contents
21
Recommended Reading
23
Terms and Abbreviations
23
Certificates
30
Safety Information and Considerations
33
Contents of this Chapter
33
Use of Safety Functions
33
Meeting the Requirements of the Machinery Directive
34
Responsibilities
34
Intentional Misuse
34
Safety-Related Parts
34
Limitations of Safe Torque off (STO) Function
34
Proof Testing
35
Safety Separation
35
ACS880 Drives with Separate Inverter and Supply Units
35
Overview
37
Contents of this Chapter
37
Intended Use of the FSO Module
37
System Description
38
FSO Module and Safety System Components
38
FSO Module Version Handling
39
Layout
40
Connections
41
Type Designation Label
41
Operational Characteristics
42
Response Times
42
FSO Diagnostics
43
I/O
43
Acknowledgement
44
Motor Speed Feedback
45
Overview of Safety Functions
50
Safe Torque off (STO)
50
Safe Stop 1 (SS1)
50
Safe Stop Emergency (SSE)
50
Safe Brake Control (SBC)
51
Safely-Limited Speed (SLS)
52
Variable Safely-Limited Speed (SLS)
52
Safe Maximum Speed (SMS)
52
Prevention of Unexpected Start-Up (POUS)
52
Safe Acceleration Range (SAR)
52
Safety Functions
53
Contents of this Chapter
53
General
54
Safety Function Request
54
Acknowledgement Methods
54
DC Magnetization and Drive Start Modes
57
Ramp Monitoring
58
Safety Function Indications
59
FSO Modes
61
FSO States
61
Transitions between FSO Modes and States
62
Cascade
63
Mute Time Feature
65
Safe Torque off (STO)
67
STO Function
67
SBC after STO
69
Step Description
70
SBC before STO
71
Safe Stop 1 (SS1)
72
SS1 with Time Monitoring (SS1-T)
73
SS1 with Ramp Monitoring (SS1-R)
75
SS1 with Speed Limit Activated SBC
77
SS1 with Speed Limit Activated SBC, SBC before STO
80
SS1 Ramp Functions When Drive Modulation Is Lost
84
Safe Stop Emergency (SSE)
86
SSE with Immediate STO
86
SSE with Immediate STO, SBC after STO
87
SSE with Immediate STO, SBC before STO
89
SSE with Time Monitoring
91
SSE with Ramp Monitoring
93
SSE with Speed Limit Activated SBC
94
SSE with Speed Limit Activated SBC, SBC before STO
98
SSE When Drive Modulation Is Lost During Deceleration Ramp
102
Safely-Limited Speed (SLS)
102
SLS with Speed below Monitored Speed
104
SLS with Time Monitoring and Speed above Monitored Speed
105
SLS with Ramp Monitoring and Speed above Monitored Speed
106
SLS Reaction When Modulation Is Lost During Deceleration Ramp, with Ramp Monitoring
107
SLS Reaction When Modulation Is Lost During Deceleration Ramp, with Time Monitoring
114
Step Description
115
FSO Boot Behavior with SLS Active
121
SLS Trip Limit Hits
121
Variable Safely-Limited Speed (SLS)
124
Variable SLS with Time Monitoring
125
Variable SLS with Ramp Monitoring
127
Safe Maximum Speed (SMS)
128
SMS Function, Version 1
129
SMS Function, Version 2
130
Prevention of Unexpected Start-Up (POUS)
131
Priorities between Safety Functions
132
Dependencies between Safety Functions
133
Profisafe
135
Contents of this Chapter
135
Introduction
135
System Description
136
Required Components
136
Tools
136
System Overview
137
Remote I/O Control
138
FSO Module Passivation
138
Profisafe Description
138
Profisafe Message Format
138
FSO Profisafe Profiles
140
FSO Module Modes and States
146
Transitions between States
155
Profisafe Response Time
158
Profisafe Watchdog Time
160
Installation
161
Configuration
161
Configuring the FB Module
161
Configuring the FSO Module
163
Configuring the Safety PLC
163
Downloading the GSD File
164
Configuring the ABB AC500-S Safety PLC
164
Configuring the Siemens SIMATIC Fail-Safe S7 PLC
181
Configuring Siemens S7-1200 PLC with TIA14
196
Fault Tracing
213
Reading Diagnostic Messages
213
Diagnostic Messages Related to F-Parameters
216
Typical Communication Errors
217
Planning for Installation
219
Contents of this Chapter
219
Requirements for Designers and Installers
219
Mechanical Installation
219
Installation Site
219
Electrical Installation
220
General Requirements
220
Connections
220
STO Cable and Data Cable between FSO Module and Drive
221
Power Supply Connection
221
Ensuring the EMC Compatibility
222
Selecting Control Cables
222
Routing the Cables
222
Standard Function and Wiring Examples
223
Installation
227
Contents of this Chapter
227
Unpacking
228
Examining the Delivery
229
Mechanical Installation
229
Installing the Module Onto a BCU Control Unit
229
Installing the Module Onto a UCU Control Unit
229
Installing the Module Onto a ZCU Control Unit
230
Electrical Installation
231
Terminals
231
Connection Procedure
232
Installation Checklists
237
Contents of this Chapter
237
Checklists
237
Configuration
239
Contents of this Chapter
239
Competence
239
Password
239
Configuring the FSO Module
240
Overview - Safety System Configuring Process
240
FSO Configuring Procedure
242
Configuring General Settings
244
Configuring the Safety Fieldbus Communication
245
How to Configure the Safety Communication with Profisafe
245
Configuring I/O
246
How to Configure I/O
246
How to Configure a Cascaded System
248
How to Configure Safety Relays
252
Configuring SBC
253
How to Configure the SBC in the STO Function
254
How to Configure the SBC in the SS1 Function
254
Configuring STO
255
How to Configure STO
256
How to Configure SBC after STO
257
How to Configure SBC before STO
258
Configuring SS1
259
How to Configure SS1 with Time Monitoring (SS1-T)
259
How to Configure SS1 with Ramp Monitoring (SS1-R)
261
How to Configure SS1 with Speed Limit Activated SBC
262
How to Configure SS1 with Speed Limit Activated SBC, SBC before STO
265
Related Safety Functions
268
Configuring SSE
269
How to Configure SSE with Immediate STO
270
How to Configure SSE with Immediate STO, SBC after or before STO
270
How to Configure SSE with Time Monitoring
271
How to Configure SSE with Ramp Monitoring
272
How to Configure SSE with Speed Limit Activated SBC
273
How to Configure SSE with Speed Limit Activated SBC, SBC before STO
277
Related Safety Functions
278
Configuring SAR
278
How to Configure Sarn
278
Configuring SLS
279
How to Configure Slsn with Time Monitoring
280
How to Configure Slsn with Ramp Monitoring
282
Related Safety Functions
283
Configuring Variable SLS
283
How to Configure Variable SLS with Time Monitoring
284
How to Configure Variable SLS with Ramp Monitoring
285
Defining the Scaled SLS4 Limit and SLS4 Trip Limits
286
Related Safety Functions
288
Configuring SMS
289
How to Configure SMS, Version 1
289
How to Configure SMS, Version 2
290
Related Safety Functions
290
Configuring POUS
290
How to Configure POUS
290
How to Configure SLS Function Behavior When Drive Modulation Is Lost
291
Celeration Ramp
292
Celeration Ramp
298
Configuring Mute Times
301
How to Determine Values for Mute Time Parameters
302
How to Configure Limit Hit Situations
302
How to Configure Mute Time for Zero Speed Detection
305
How to Configure Mute Time for SBC Speed Limit Detection
306
How to Configure Mute Time for Monitoring Start
306
FSO-12 Parameters
309
Contents of this Chapter
309
Status and Control Words
347
Start-Up
353
Contents of this Chapter
353
Safety Considerations
353
Checks
354
Verification and Validation
355
Contents of this Chapter
355
Verifying the Achieved SIL/PL Level
355
Purpose of the Validation Testing
355
Preconditions for Validation Testing
356
Validation Procedure
356
General
356
Validation Test Reports
357
Competence
357
Tools
357
Validation of ACS880 Drive Firmware
358
Validation of the Profisafe Connection
358
Validation of Safety Functions
359
Validation of Redundant Inputs
359
Validation of Safety I/O's
360
Validation of the General Settings
360
Validation of the STO Function
361
Validation of the SBC Function
362
Validation of the SSE Function
364
Validation of the SS1 Function
367
Validation of the SLS Functions
369
Validation of the Variable SLS Function
371
Validation of the SMS Functions
373
Validation of the POUS Function
375
Validation of the Cascaded Safety Function
376
Proof Test Intervals During Operation
377
Residual Risks
377
Fault Tracing
379
Contents of this Chapter
379
Status Leds
379
Event Types
380
Event Code Decoding with Drive Composer Pro PC Tool
381
Faults, Warnings and Events
382
User-Selectable Events for Function Requests
391
User-Selectable Events for Limit Hits and Special Events
392
User-Selectable Events for Safety Fieldbus Failures
394
Auxiliary Codes
394
FSO Recovery
394
External Fault
394
Internal Fault
395
Reporting Problems and Failures
395
Maintenance
397
Contents of this Chapter
397
Planning
397
Tools
397
Component Replacement in the Safety Circuit
398
Before Component Replacement
398
Replacing the FSO Module
399
Installing the FSO Module to Another Drive
399
Replacing the Control Unit of the Drive
400
Replacing the Control Unit of the Drive with a Different Type of Control Unit
400
Replacing the Memory Unit or Updating the Firmware of the Drive
401
Replacing a Power Unit, or Its Circuit Boards or Wirings
401
Replacing the Motor or Motor Cable
402
Replacing the FB Module in Profisafe Network
402
Start-Up and Validation Test
402
Factory Reset
402
Drive Control Board Boot
403
Updates
404
Proof Tests
404
Decommissioning
404
Technical Data
405
Contents of this Chapter
405
Electrical Data
405
Profisafe and Related Network Devices
406
Control Connection Data
406
Terminal and Cable Entry Data for the Control Cables
407
STO Cable and Data Cable between FSO Module and Drive
408
Tightening Torques
408
Size and Weight
408
Cooling
408
Compatible Motor Types
409
Speed Estimation
409
Ambient Conditions
409
Safety Functions
411
Safety Data
411
General
411
Basic Safety Data
413
FSO Safety Calculations Guide (Without Profisafe)
414
FSO Safety Calculations Guide (with Profisafe)
418
Relevant Failure Modes
418
Response Times
420
Ordering Information
421
Related Standards and Directives
422
Dimension Drawings
423
Further Information
425

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ABB FSO-12 User Manual

ABB FSO-12 User Manual (388 pages)

Safety functions module

Brand: ABB | Category: Control Unit | Size: 9 MB

Table of Contents

Table of Contents
5
1 Safety Instructions

13
- Contents of this Chapter
  13
- Use of Warnings
  13
- Electrical Safety Precautions
  14
2 Introduction to the Manual

15
- Contents of this Chapter
  15
- Exclusion of Liability
  15
- Applicability
  15
- Compatible Products
  16
  - Drives and Option Modules
    16
  - Controller Stations
    16
  - Tools
    16
- Supported Safety Functions
  16
- Target Audience
  17
- Purpose of the Manual
  17
- Contents
  17
- Recommended Reading
  19
- Terms and Abbreviations
  19
- Certificates
  25
3 Safety Information and Considerations

27
- Contents of this Chapter
  27
- Meeting the Requirements of the Machinery Directive
  27
- Responsibilities
  28
- Intentional Misuse
  28
- Safety Considerations
  28
  - Response Times
    28
  - FSO Diagnostics
    28
  - I/O
    29
  - Acknowledgement
    30
  - Motor Speed Feedback
    30
  - Proof Testing
    34
  - Safety Separation
    35
  - ACS880 Drives with Separate Inverter and Supply Units
    35
4 Overview

37
- Contents of this Chapter
  37
- System Description
  38
  - FSO Module and Safety System Components
    38
  - FSO Module Version Handling
    39
  - Layout
    40
  - Connections
    41
  - Type Designation Label
    41
  - Operational Characteristics
    42
- Overview of Safety Functions
  42
  - Safe Torque off (STO)
    43
  - Safe Stop 1 (SS1)
    43
  - Safe Stop Emergency (SSE)
    43
  - Safe Brake Control (SBC)
    43
  - Safely-Limited Speed (SLS)
    44
  - Variable Safely-Limited Speed (SLS)
    44
  - Safe Maximum Speed (SMS)
    44
  - Prevention of Unexpected Start-Up (POUS)
    44
5 Safety Functions

45
6 Profisafe

137
- Contents of this Chapter
  137
- Introduction
  137
- System Description
  138
  - Required Components
    138
  - Tools
    138
  - System Overview
    138
- Remote I/O Control
  140
- FSO Module Passivation
  140
- Profisafe Description
  141
  - Profisafe Message Format
    141
  - FSO Profisafe Profiles
    142
  - FSO Module Modes and States
    148
  - Profisafe Response Time
    160
  - Profisafe Watchdog Time
    162
- Installation
  164
- Configuration
  165
- Fault Tracing
  194
7 Planning for Installation

201
- Contents of this Chapter
  201
- Requirements for Designers and Installers
  201
- Mechanical Installation
  201
  - Installation Site
    201
- Electrical Installation
  202
  - General Requirements
    202
  - Connections
    202
  - STO Cable and Data Cable between FSO Module and Drive
    203
  - Power Supply Connection/Cables
    203
  - Ensuring the EMC Compatibility
    203
  - Selecting Control Cables
    203
  - Routing the Cables
    204
  - Standard Function and Wiring Examples
    204
8 Installation

209
- Contents of this Chapter
  209
- Unpacking
  210
- Checking the Delivery
  210
- Mechanical Installation
  211
- Electrical Installation
  212
  - Terminals
    212
  - Connection Procedure
    213
9 Installation Checklists

217
- Contents of this Chapter
  217
- Checklists
  217
10 Configuration

219
- Contents of this Chapter
  219
- Competence
  219
- Password
  219
- Configuring the FSO Module
  220
  - Overview - Safety System Configuring Process
    220
  - FSO Configuring Procedure
    222
- Configuring General Settings
  224
  - How to Configure General Settings
    224
- Configuring the Safety Fieldbus Communication
  225
  - How to Configure the Safety Communication with Profisafe
    225
- Configuring I/O
  226
  - How to Configure I/O
    226
  - How to Configure a Cascaded System
    227
  - How to Configure Safety Relays
    230
- Configuring SBC
  231
  - How to Configure the SBC in the STO Function
    232
  - How to Configure the SBC in the SS1 Function
    233
- Configuring STO
  234
  - How to Configure STO
    234
  - How to Configure SBC after STO
    235
  - How to Configure SBC before STO
    236
- Configuring SS1
  237
- Configuring SSE
  248
- Configuring SAR
  257
  - How to Configure Sarn
    257
- Configuring SLS
  258
- Configuring Variable SLS
  262
- Configuring SMS
  269
  - How to Configure SMS, Version 1
    269
  - How to Configure SMS, Version 2
    270
  - Related Safety Functions
    270
- Configuring POUS
  271
  - How to Configure POUS
    271
- How to Configure SLS Function Behavior When Drive Modulation Is Lost
  271
  - Tion Ramp
    272
  - Tion Ramp
    278
- Fine-Tuning the Configuration
  282
11 FSO-12 Parameters

285
- Contents of this Chapter
  285
- Status and Control Words
  319
12 Start-Up

325
- Contents of this Chapter
  325
- Safety Considerations
  325
- Checks
  325
13 Verification and Validation

327
- Contents of this Chapter
  327
- Verifying the Achieved SIL/PL Level
  327
- Purpose of the Validation Testing
  327
- Preconditions for Validation Testing
  328
- Validation Procedure
  328
  - General
    328
  - Validation Test Reports
    329
  - Competence
    329
  - Tools
    329
  - Validation of the Profisafe Connection
    330
  - Validation of Safety Functions
    331
  - Validation of Redundant Inputs
    331
  - Validation of Safety I/O's
    332
  - Validation of the General Settings
    332
  - Validation of the STO Function
    333
  - Validation of the SBC Function
    335
  - Validation of the SSE Function
    337
  - Validation of the SS1 Function
    340
  - Validation of the SLS Functions
    342
  - Validation of the Variable SLS Function
    344
  - Validation of the SMS Functions
    346
  - Validation of the POUS Function
    348
  - Validation of the Cascaded Safety Function
    349
- Proof Test Intervals During Operation
  350
- Residual Risks
  350
14 Fault Tracing

351
- Contents of this Chapter
  351
- Status Leds
  351
- Event Types
  352
- Event Code Decoding with Drive Composer Pro Tool
  352
- Faults, Warnings and Events
  353
- Auxiliary Codes
  362
- Reporting Problems and Failures
  362
15 Maintenance

363
- Contents of this Chapter
  363
- Planning
  363
- Tools
  363
- FSO Module Replacement
  363
  - Replacing the FSO Module
    364
- Drive Replacement
  365
  - Reinstalling the FSO Module to Another Drive
    365
- Drive Firmware Update
  366
  - Updating the Firmware of the Drive Where the FSO Module Is Installed
    366
- FENA Module Replacement
  367
  - Replacing the FENA Module
    367
- Factory Reset
  368
- Drive Control Board Boot
  369
- Updates
  369
- Proof Tests
  369
- Decommissioning
  370
16 Technical Data

371
- Contents of this Chapter
  371
- Electrical Data
  371
- Profisafe and Related Network Devices
  371
- Control Connection Data
  372
- Terminal and Cable Entry Data for the Control Cables
  372
- STO Cable and Data Cable between FSO Module and Drive
  373
- Tightening Torques
  373
- Size and Weight
  373
- Cooling
  373
- Speed Estimation
  374
- Ambient Conditions
  374
- Safety Functions
  375
- Safety Data
  376
  - General
    376
  - Basic Safety Data
    378
  - Safety Data for some Typical Configurations
    380
  - Relevant Failure Modes
    381
  - Response Times
    382
- Related Standards and Directives
  384
17 Dimension Drawings

385
Further Information

387

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