Welcome to the safety functions configuration training module for ACS880 Cabinet-builtindustrial drives.

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After viewing this presentation you will be able to describe:• The functionality of cabinet-built safety options and predefined I/Os for different

safety options.• The principles in network safety options.• How the standard options are preconfigured and how to modify customer specific

values.• The FSE pulse encoder interface parameterization.You will also be able to verify the integrity of the FSO circuit, back up an FSOconfiguration, and change the emergency stop function stop category from 0 to 1.

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The FSO safety module allows implementing integrated safety functionalities andprovides complete safety solutions.The FSO has several digital safety inputs and outputs, which are used to make the safetyoptions with proper additional components.Correct parameter settings are configured with the Drive composer pro PC tool.In this presentation the basic wiring of safety components is illustrated from the FSOmodule to the drive. Also the parameter lists related to the pre-configured safetyoptions will be presented.For the FSO-12 module the option code is +Q973 and for the FSO-21 +Q972.

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There is one important difference between the FSO modules: The FSO-21 module offersa possibility to use measured motor speed data with the FSE-31 pulse encoder interface.The FSO-21 module also has additional safety functions: Safe speed monitoring (SSM)and Safe direction (SDI).The FSO-12 is incompatible with the FSE-31. The FSO-12 uses only estimated motorspeed for functional safety purposes.

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The FSO safety options module connects to the inputs of the customer terminal,illustrated on the slide.The FSO I/Os are brought to the customer extension terminals X68. The terminalnumbers are fixed to the safety option: Here is an example of a safety optionscombination (+Q973 and +Q978). Test pulses and grounds are always bridged in X68.The actual delivery might also include other external customer terminals such as X951and X957.

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The pulse encoder interface module FSE-31 is intended to be used for functional safetypurposes with FSO-21 safety functions module. The same pulse encoder interface is alsoused for motor control. The FSE-31 communicates with the ACS880 inverter unit and theFSO-21 via a control unit. The FSE module supports a differential safety encoder. The FSEencoder interface mounts on slot 2 by default. The interface uses same external powersource as the FSO-21 module and it requires a differential safety encoder for the motor.

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This slide illustrates the FSE-31 interface encoder cable connection to the X31 connector.The interface module has two encoder interface connectors, X31 and X32. The X31 is inuse. The pins are allocated from top to bottom in ascending order. The 24 volt output todifferential safety encoder is connected to pin 1, signal ground to pin 2 and signalchannels to pins 3 to 8. Encoder cable shield is connected to pin 9. The Z-channels (7 and8) are in use with the FSE module. (The FSE module requires an external 24 volt inputpower source, connector X81.)

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Configuring the FSE pulse encoder. FSO parameters from groups 91 and 92 on whitebackground are common both with FSO-21 and inverter unit firmware. Theseparameters are set to the inverter unit during control unit reboot. If the user has toreconfigure the parameters on white background, they have to be set via the FSOmodule. (E.g. during commissioning, the FSE parameters have to be set via the FSOmodule.)The parameters on blue background exist only in the FSO-21. E.g. encoder count(200.232) and fault reaction function (S_ENCGEN.11) from the FSE-31 failure are definedwith these parameters.In addition to these functions, the parameters on green background are also set at thefactory. The green parameters exist only in the inverter unit firmware and are set forencoder cable fault diagnostics.

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Here are listed the safety options for the ACS880 cabinet-built drives. The FSO safetyoptions module is included in each option with code +Q973 for the FSO-12 and +Q972for the FSO-21.It is possible to combine safety options together to establish required functionalities.

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Here is an illustration of the FSO option +Q979, Emergency stop with STO, and itscomponents.In this example the control unit, the FSO and the FSE modules must be powered with anexternal power supply to work properly. Wire harnesses are installed at the factory. Theuser may not change any component or wirings without performing verification andvalidation afterwards to the system.With option +Q979 emergency stop is not connected to the main contactor, i.e. the DC-link is on during stop.When options +Q978 and +Q979 are implemented with the FSO-21 and the FSE-31:• Measured motor speed data is used for functional safety purposes instead of

calculated speed estimate.• Motor speed data is available also when modulation is stopped.

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Here is an example of an emergency stop procedure in single drives. (Activation and de-activation)The drive is running at first, test pulses are functioning and their indication LEDs are lit inthe FSO module. As the user pushes the emergency stop button, voltage to digital inputsX113.1 and X114.1 goes down and the FSO starts controlling the drive bringing it to aSafe torque off ( STO) state. The STO LED also activates in the FSO module. When theuser lifts up the emergency button and resets the system, the FSO receives anacknowledgement signal that the emergency stop has been recognized and drive isreset. The pilot light goes off and the drive is ready to run.The +Q979 option functionality is illustrated on the next slides.Finally all the running state LEDs should be lit. If some of the DI indication LED’s aremissing or the fault LED is lit, there is a mistake in the input wiring. If Fault or STO LEDsare lit there might be also problem in parameterization.

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Here is shown Emergency stop option +Q979 basic function. Active signals are shownwith red and disabled signals with dashed black line.In this state the drive is modulating and the motor is running. Test pulses are received inthe digital input terminals (DI) X113.1 and X114.1 and STO connector receives the activesignals (high) from the FSO.

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When the user activates the emergency stop, voltage goes down in digital inputs X113.1and X114.1. The FSO disconnects the STO supply and the STO signals fall down in theinverter module. Simultaneously the reset pilot light switches on to indicate emergencystop situation. As a result the drive modulation is stopped and the motor is cut off frompower supply.To restore the drive to run state, the user must pull up the emergency stop button andpress the reset button. Depending on the parameter 31.22, the drive might need to bereset.

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Here are the +Q979 option connections made from the FSO module to the customerterminal.The parameters on green background are preconfigured by ABB and the parameters onyellow background can be adjusted according to the customers needs.

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Here is an illustration of the single drive option +Q978 Emergency stop with Maincontactor (MC) or Main circuit breaker (MCB).This safety option includes the presented components.In this presentation switching device means main contactor/circuit breaker.The +Q978 option functionality is illustrated on the next slides.

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Here is the connection diagram of the Emergency stop option +Q978, which opens themain contactor (MC) or main circuit breaker (MCB). (Active signals are shown with redand disabled signals with dashed black line.)In the beginning the drive is modulating and the motor is running. Test pulses arereceived in the digital input terminals X113.1 and X114.1. The STO connector gets active(high) signals from the FSO.Compared to the previously presented option +Q979, in this option additional inputsand outputs from the FSO are used to control and supervise a breaker. The standardclosed supervision contact of the device is wired to DI X113.2, which receives the testpulse signal when the device is in open position. When the drive is running, the device isclosed and input voltage is down. The supply switching device is controlled by a safetyrelay, which is wired to DO X114.9. In the picture the relay output is active, safety relay isenergized and the main contactor is closed.

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When the user activates the emergency stop, DI X113.1 and DI X114.1 stop receiving thetest pulses. The FSO disconnects the STO supply and STO signals go low in invertermodule. At the same time reset pilot light DO X114.7 switches on indicating emergencystop situation. Additionally the FSO deactivates the D O X114.9 and safety relay de-energizes, which opens the supply disconnection device. As a result drive modulation isstopped, supply is disconnected and motor stops receiving power.To restore the drive to run state, user must pull the emergency stop button up and pressthe reset button. Depending on the parameter 31.22, drive might need to be reset.

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Here are the +Q978 option connections from the FSO module and the relatedparameters. Parameters on green background have been preconfigured by ABB andparameters on yellow background can be adjusted according to the customers needs.

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Here are the components included in the +Q950 Prevention of unexpected startup(POUS) single drive option.The POUS option circuit diagrams and functionality is illustrated on the next slides.

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The drive is modulating and motor is running. Test pulses are received in the DI terminalsX113.3 and X114.3.

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The POUS function should be used after the user has stopped the drive. Now drivemodulation is stopped and motor is not powered. The POUS switch is disengaged andthe digital inputs X113.3 and X114.3 contacts are disconnected from the test pulses. ThePOUS pilot light switches on simultaneously to indicate POUS activation. Inverter side isnot disconnected from the supply.To restore the drive to run state the user must turn the POUS switch back on.

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Here are the multidrive POUS connections from the FSO and the related parameters.Parameters on green background are preconfigured by ABB and parameters on yellowbackground can be adjusted according to the customers needs.

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The drive is modulating and motor is running. Test pulses are received in the DI terminalsX113.3 and X114.3.

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Here are the FSO-21 parameters related to SLS function configuration with option +Q965for ACS880 cabinet-built single drives. The SLS inputs and one pulsed output areconfigured for SLS1 function. Option +Q965 includes also safe speed monitoringfunction, SSM. The SSM configuration is presented later with option +Q965 for ACS880multidrives. (Parameters on green background are preconfigured by ABB and parameterson yellow background can be adjusted according to the customers needs.)

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In multidrive applications, safety functions can be implemented by linking multiple FSOmodules.This slide illustrates the multidrives emergency stop option +Q979 where multiple FSOsare grouped together to create an emergency stop network.The FSO inputs are powered with an external 24 V supply which is disconnected with asafety relay.As the emergency stop button is pushed, the FSOs do not receive signal in DI X113.1 andDI X114.1. Then STO is activated for each inverter unit.If the customer order consist of several line-ups, the emergency stop network isgalvanically isolated between the line-ups.

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Here are the multidrive emergency stop option connections from the FSO and therelated parameters. (Parameters on green background are preconfigured by ABB andparameters on yellow background can be adjusted according to the customers needs.)

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The following video demonstrates the configuration of the Emergency stop option+Q979 for multidrives. Ramp monitoring is chosen as the monitoring method.

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The parameter values used in this video are only examples. All the motor specific valuesand delay times depend on application and motors used. In this example the final safetyconfiguration is done off-line to the pre-configured safety file delivered to the customerby ABB. The pre-configured safety file is already uploaded to the PC from the FSO. Themodifications to safety parameter settings are done with Drive composer PC tool. Themodified safety file must be downloaded to the FSO after these parameter settings aredone.Open Drive composer pro. Click demo for off-line configuration.To change the stop category from coast stop to ramp stop, click the name of the driveunder the drives menu and choose, safety settings 2.Open the previously saved safety file.A list of safety parameters opens with pre-configured values.Change the value of the chosen parameter by clicking the parameter value. SAR1parameters are set for ramp monitoring. Target ramp slope is set. Speed scaling andmotor nominal values are set according to the motor. Scroll down to see otherparameters.Trancient mute time is set. Zero speed limit is set to a suitable value for STO activationafter ramp stop. The FSO STO input A is set to none. Make sure not to configure samedigital inputs for FSO STO function and SS1 function. If both functions are configured tosame input, coast stop is performed instead of ramp stop due to function priority.SS1 function is activated and all the parameters of the SS1 will become visible. For SS1

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input A, we choose the input that was previously in use in STO function. SS1 input B is notin use and is set to none. In this example monitoring method is set to ramp. Since thereare no SS1 outputs, they are set to none.Next we set the SAR ramp range and ramp limits for the ramp monitoring. Maximumramp slope is set to higher value than the target ramp slope. Minimum ramp slope is notmonitored in this example and is set to zero.Save the newly configured safety file to the PC. Rename the safety file for easier use.After the off-line configuration, download the safety file to the FSO module before use.Download the safety file with the Drive composer pro PC tool when connected to theinverter unit: Open the safety file and click download to FSO. At this point the PC tool willask for a password. When the file is downloaded successfully, the new safetyconfiguration is ready for use.

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Here is an illustration of the Prevention of unexpected start-up (POUS) option +Q950 inmultidrives.The POUS option can be used in multidrives in a similar way as in single drives. Inmultidrives, in addition to the FSO single setup, several inverter units can be groupedtogether to form an FSO master-follower network.The master receives a POUS request in DI X113.3 and DI X114.3 as the user turns thePOUS switch. The POUS pilot light switches on and the STO for the correspondinginverter unit is activated. At the same time the followers receive the same POUS requestthrough the master’s DO X113.9 and DO X114.9 and they activate the STO for thecorresponding inverter units as well. If the POUS is activated when the motor is running,a coast stop is executed.

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Multidrives Prevention of unexpected start-up option +Q950.Here are the connections made from the FSO and the related parameters.(Parameters with green color are preconfigured at the factory by ABB. No need tochange parameters at the site for this configuration.)

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Here is illustrated the Safely-limited speed (SLS) option +Q965/+Q966 in multidrives. TheSLS supervises and controls that the motor does not exceed the speed configured by theFSO safety parameter.Every control unit has its own SLS switch and an indication output. The SLS networks areconfigured at the factory.All the FSOs individually supervise and control that the motors’ speeds are below thelimit defined by the FSOs parameters.

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Here is a multidrive example of the Safely-limited speed (SLS) FSO parameters. The SLS1function is used in the FSO module. One redundant SLS input and one pulsed output areconfigured for the SLS function. SLS network is wired at ABB factory when SLS request isintended to activate safely-limited speed in more than one inverter unit at the sametime. In that case the SLS is activated with one 24 V powered switch for all the inverterunits in the network. Otherwise, there is one separate SLS switch for every inverter unit.(Parameters on green background are preconfigured by ABB and parameters on yellowbackground can be adjusted according to the customers needs.)

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Here are the safe speed monitoring (SSM) connections and the FSO parameters of thisconfiguration for cabinet built drives with option codes +Q965 and +Q966 with FSO-21module. One pulsed output is configured for the SSM and the safety function isconfigured to be permanently on. The parameter settings for the SSM function withoption +Q965 with ACS880 cabinet-built single drives are similar as with multidrivesshown here.

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Here is an illustration of the PROFIsafe +Q982 option. This example consists of thefollowing components:• ACS880 drive• FENA-21 fieldbus module• FSO safety functions module• Safety master programmable logic controller (PLC) supporting PFOFIsafeThe option does not include PROFINET cabling to connect the drives together.

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Here is an illustration of the PROFINET network, established between inverters. TheEthernet switches are PROFINET certified and they include important quality featuressuch as media redundancy protocol (MRP). The FENA-21s fieldbus modules areconnected to the switches. In basic design, in inverters R1i to R5i, the FENA-21 modulesare chained together to save switch ports. The cabling is also PROFINET certified. Thegreen color differentiates it from basic Ethernet cable. The green cable is used inside theline-up construction. In this picture the customer connection with optical cable is shownwith black color.

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It is highly recommended to always save the latest version of the safety configuration filein addition to the pre-configuration file delivered by ABB. The FSO module must becompletely configured in the case of· Replacing the FSO module with a new one· Updating the firmware in the inverter units· FSO factory resetRe-configuring can be done by downloading the existing safety file with applicationspecific safety parameter values.

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Here is a summary of the discussed topics.

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