Welcome to the Safety functions training module for ACS880 cabinet-built industrial drives.

Transcription

1 Welcome to the Safety functions training module for ACS880 cabinet-built industrial drives. 1

2 In this presentation we will discuss safety options for ACS880 cabinet-built drives, FSO-12 safety functions module and certificates. 2

3 Here are the objectives of this presentation. 3

4 This ACS880 compatibility map shows how safety is integrated into the ACS880 series: Safe Torque Off comes as a standard feature for the ACS880. The safety functions module, FSO, is provided as an additional function module which will include the functions shown on the slide. The safety options utilize these functions. 4

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6 The Safe torque-off (STO) functionality comes as standard with the ACS880. It is a safety rated circuit that removes motor torque by shutting down the power electronics. STO also saves installation space and lowers costs. 6

7 The ACS880 STO function can be connected to any safety device, safety relay or safety PLC and it is tolerant to diagnostics test pulses from safety PLC. The STO can be supplied internally or by an external power supply. It has a response time of less than 50ms. The STO must be used redundantly: Both input channels must be used for the same function for the STO to work properly. 7

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9 In ACS880 cabinet-built drives the FSO safety functions module makes it possible to link the safety functions together. With the FSO module it is possible to implement the same functionalities as with safety relays. 9

10 The FSO module uses a speed estimator to implement safe speed and ramp monitoring without an encoder. The function uses two independent speed estimates that are compared in the safety functions module. This function can only be used in applications where movement slows down when the drive is not running. (When there is no load that would continue rotating the motor or preventing it from stopping.) The motor control has to work accurately, i.e., a complete motor ID run is required during commissioning. FSO-12 module does not support crawl speed limits lower than 30 rpm with safety functions applications. 10

11 The FSE-31 pulse encoder interface is used for both motor control and functional safety purposes. Inverter can be configured to use speed estimate in case of an encoder- or an encoder interface fault. A differential safety encoder is required for the motor. 11

12 The FSO-12 safety module is available with the option code +Q973. Available safety options for cabinet built drives with the FSO-12 are: Prevention of unexpected start-up (With FSO; POUS +Q950 +Q973) Emergency stop can be configured stop category 0 or 1 with STO (With FSO; +Q979 +Q973) In ACS880-07/-17/-37 cabinet-built single drives: Emergency stop category 0 or 1 with a contactor and STO (With FSO; +Q978 +Q973) In ACS880 multidrives: Safely-limited speed without encoder (With FSO-12; +Q966 +Q973) The FSO-12 module supports PROFIsafe. (FSO-12 rev. C and later) (Safe outputs: Indication of safety function status, actuating auxiliary devices) 12

13 The FSO-21 safety module is available with the option code +Q972. In addition to FSO-12 safety functions, the FSO-21 includes the following functions: Safely-limited speed SLS with an encoder (+Q965 +Q972). The +Q965 also includes Safe speed monitoring SSM function. In ACS880 multidrives: Safely-limited speed without encoder (+Q966 +Q972). The +Q966 option also includes the SSM function. Safe direction (SDI) function. The FSO-21 module supports PROFIsafe (FSO-21 rev. B and later). 13

14 The units marked with a red exclamation mark do not include an FSO module. The FSO module is included in the inverters marked with a green tab. In frame R8i, the connection cable connects the inverter modules into the same FSO safety module. The FSO module and the STO safety function must not be used in supply or brake units: The risks and hazards that the safety functions reduce are related to the movement of the motor. (ZCU, BCU = Control units) 14

15 It is also possible to order the FSO module only, without any external hardware: The module is not preconfigured to perform wanted safety options. However, the FSO only module is mounted and connected to the control board: The communication cable and the STO cable are installed. Power supply is installed for the FSO and the FSE-31 module. To ease customers cable connections, the FSO module is wired into a customer terminal block. 15

16 When ordering the FSO-12 module without any pre-configured safety options, make sure that the end user does not require any factory configured functions. In multidrives, it is not possible to specify any FSO networks for the +Q973 FSO only module. (Grouping of FSO modules) 16

17 Here are listed some of the main properties of the Prevention of unexpected start-up (POUS) option +Q950. The FSO module will come to each inverter included in the POUS circuit. The POUS is classified up to SIL 3 and PL e levels. 17

18 The customer I/O terminal connects the FSO module to customers applications. The switch and lamp in the example picture are customers equipment. 18

19 The Emergency stop option +Q979 is configured as stop category 0 (immediate coast stop + STO) by default. The function can be configured as stop category 1 (ramp stop + STO) with Drive composer pro tool. The benefit compared to a safety relay is that the FSO can be configured to actively monitor the stopping of the drive. This option is available in single and multidrives and has a safety integrity level up to SIL 3. 19

20 Here is an illustration of an assembly of the Emergency Stop option, configurable to stop category 0 or 1, with STO function and FSO module. 20

21 Emergency stop with contactor and FSO module is only available in single drives. The emergency stop option +Q978 with contactor operates similarly as with +Q979 option. However, when opening the main contactor, the FSO function opens the STO as well. Safety level with this function is up to SIL 3. 21

22 Here is an illustration of an assembly of the Emergency Stop option with contactor, configurable to stop category 0 or 1, with STO function and FSO module. 22

23 The Safely-Limited Speed (SLS) option +Q966 is available for multidrives and comes with the FSO-12 module. Networking is possible similarly as with the POUS option. No speed encoder is needed. 23

24 Here is an example illustration of an assembly of the Safely-Limited Speed (SLS) option +Q966, with FSO module. The FSO output also allows utilizing a safe gate functionality. 24

25 In SLS and POUS networks networking as a chain (cascaded) in a closed loop is not supported: There are not enough available inputs for feedback. It is possible for the networks to continue from one line-up to another. 25

26 The Safely-limited Speed (SLS) function without an encoder is not available as a preconfigured option: Customer can configure the option using Drive Composer Pro tool. (Correspondingly for Safe Brake Control (SBC) and Safe Maximum Speed (SMS) functions). Furthermore, the SLS without an encoder is available for ACS880-07/-17/-37 single drives, but does not have its own option code. 26

27 This slide shows the equivalent safety options of the FSO module and ATEX. The following slides illustrate the safety option combinations in cabinet-built single and multidrives, and the compatibility of ATEX and Functional safety options. 27

28 Here is a table of safety options combinations in cabinet-built single drives. You can configure additional functions to remaining free I/Os. 28

29 Here is a table of safety options combinations in multidrives. In multidrives, the option code +Q978 is unavailable but +Q966 is available. The following two slides illustrate the compatibility of ATEX and Functional safety options. 29

30 The FSO safety options with ATEX certified temperature protection functions are also available for the ACS880. (Environment with explosive atmosphere.) Compatibility possibilities of ATEX and FSO FS functions in ACS880 cabinet-built single drives. 30

31 Compatibility possibilities of ATEX and FS functions in ACS880 multidrives. ATEX and Emergency stop with safety relay and contactor is possible with multidrives. 31

32 The FSO safety module has several customer benefits. SIL and PL levels are guaranteed for the safety options. The used components are certified and the FSO can be parameterized at factory to perform ordered functions. The safety logic unit of the functions is certified FSO module. It is integrated with the ACS880 control unit and all functions utilize the drive internal STO function. 32

33 All standard and tailored safety systems (options) are done according to TÜV Nord certified process. With multidrives, Grouping of safety options is possible. The customer can change the safety option settings with the Drive composer pro tool. 33

34 ACS880 cabinet-built drives have competency requirements for all ABB personnel and authorized partners who perform commissioning, maintenance or other service actions to configure the FSO module. The Drives factory stores the FSO parameter settings file of each delivered safety option. Customer is responsible for any changes in the FSO parameter settings. Safety option manuals describe competence requirements. 34

35 ABB issues a declaration of conformity according to the European Machinery Directive for all safety functions of the drive and it complies with the machinery safety standards. Here are the key points. 35

36 All the necessary manuals are included in the delivery. Each unit has its own manual. If the customer is ordering an empty FSO module, only the FSO manual is included. 36

37 The functional safety design tool helps the customer to design, verify and document machine safety functions according to international safety requirements. A list of features is shown on the slide. 37

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39 An independent certification body, TÜV Nord, has granted ABB Drives Helsinki a Functional Safety Management (FSM) certificate for the offer-order-delivery processes of ACS880 multidrives and cabinet-built single drives. The FSM certificate covers the most relevant functional safety standards of ABB business. (Listed on the slide.) 39

40 The FSM certificate has several benefits. The certificate issued by TÜV Nord guarantees that the offer-order-delivery processes meet the functional safety (FS) requirements illustrated on the slide. It also provides an ability to tailor FS solutions into ACS880 cabinet-built drives, based on application specific requirements, to optimally serve and protect the customer s process. 40

41 Other benefits of the TÜV Nord functional safety management certificate are presented on the slide. 41

42 Here are listed some of the certification features of the Safe torque off function. 42

43 The FSO module and the ACS880 drive are certified as a single unit (a safety component). The certificate has a tracking list of all certified drive types. 43

44 Here is the certificate for the Functional safety design tool (FSDT-01). Please see the support materials at the end of the presentation for more information about FSTD. 44

45 ABB Drives Helsinki (FIDRI) upholds the Functional safety policy and maintains the safety management system in accordance to international safety laws and requirements. FIDRI is committed to functional safety through promotion, development etc. FIDRI promotes organizational safety culture and ensures that the people associated with safetyrelated ABB products have necessary competencies. FIDRI s responsibility is to communicate and implement safety policy throughout Drives, Helsinki. 45

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47 Here is a summary of the discussed topics. 47

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49 Link to a Drive-based functional safety site, ABB LV AC drives. 49

50 The following documentation is available: Functional safety design tool user s manual A general guide about safety and functional safety 50

51 The following documentation is available: Drive-based functional safety Flyer Technical guide no. 10 about functional safety A general guide about safety and functional safety 51

52 The following documentation is available: Safety functions module for extending application safety brochure The FSO-12 user s manual 52

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