Welcome to the overview of ACS880 functional safety, FSO-11 Safety functions module.

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1 Welcome to the overview of ACS880 functional safety, FSO-11 Safety functions module. 1

2 The e-learning sessions about FSO-11 safety functions module contain the following topics. A general overview More detailed view of Safety functions How to create safety functions: FSO-11 mounting Connecting inputs & outputs Configuration Verification, validation and documentation Servicing the FSO-11 module Reference information This e-learning presentation gives an overview of the FSO-11. 2

3 What are market drivers and trends in functional safety? Harmonized standards are made to implement safety with electronics (Machinery application standards EN ISO , EN IEC 62061). Safety functions are being offered in the market and integrated into motion control since they are approved in the standards. A new standard for power drive systems safety functions is made and widely appreciated (EN IEC ). Safety functions include among others, emergency stopping, prevention of unexpected start-up and safe speed related functions. The integrated safety is modular, versatile and intelligent. Once connected, it can be configured and modified into multiple functions within one system. Instead of being single components, the safety functions compose complete solutions that consist of several features. Currently, this concept has turned out to be popular in the safety market. 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-11 will be provided as an additional option which will include functions. SS1 Safe Stop 1 SSE Safe Stop Emergency SLS Safely-Limited Speed SBC Safe Brake Control, and SMS Safe Maximum Speed 4

5 The Safe Torque Off, STO, is a standard safety function in ACS880 and it s safety performance is classified as SIL 3 class, or PL e level. With the additional safety functions module FSO-11, the safety performance class of the ACS880 remains at SIL 3, or PL e level. 5

6 The additional functions provided by the FSO-11 are mainly targeted for industrial applications. FSO-11 also includes Safe inputs and outputs, Self-diagnostics (software, memory and parameters checked at start-up), wire diagnostics (test pulses, explained later) and safety data available for system design and system level calculations. Note: ACS mostly refers to such safety functions as STO, SS1, etc. When discussing the larger cabinet installations, the offering contains also machine level functions such as Emergency stop and Prevention of unexpected start-up. These functions can constitute a machine safety system or a part of it. 6

7 FSO-11 Characteristics and benefits: The FSO-11 module is quick to install It has pre-programmed functions that can be edited with Drive composer pro PC tool The FSO-11 module is compatible with both ACS880 single- and multidrives The module provides alternative standard mounting positions for flexibility It has a robust aluminum housing that protects it from vibration, extracts excess heat, and shields the circuits from EMC disturbances 7

8 Integrated safety reduces overall system costs: Safety functionality is designed to work seamlessly with the drive. It has ready-made and verified safety functions The safety functions module is small Motor contactors are not needed with ABB s integrated safety functions: Safe torque-off ensures safe state transition and fast restarting There is no need for a separate encoder since the drive system provides sensorless speed monitoring (This function is design based, not acceptable with all designs) The integration reduces cabling connections and optimizes efficiency in many levels Reduced design efforts connect and configure Certified safety building blocks with safety data Improved system cycle times, fast reaction due to STO Safe speed without external sensors in many cases Reduced wiring (no external cabling) The drive s regular inputs and outputs are not used for safety 8

9 A single tool can be used to configure the drive and the safety system 8

10 Here are the FSO-11 module details: STO Output to the drive and power supply connection are located at the top (max current consumption is 2 amperes) Data connections (opto-isolated) are located at the side of the module (left side in the picture) Status LEDs are mounted in front of the module, below them are the input and output LEDs At the bottom of the module are the connections for inputs, outputs, and the wiring test pulse supply The factory reset button is located in the lower right corner (picture) The module has four mounting points for screws located at both sides of the module The whole module is isolated from the drive: If an error occurs in the drive, the module will not be affected, and vice versa. 9

11 The inner structure of the FSO-11 module is introduced here. The module has three layers of circuit boards: The top layer includes the power supply and LED indicator lights The middle layer consists mainly of two CPUs. It also includes an FPGA logic for communications, two operating systems (one for each CPU), and one common application SIL 3 level software. The architecture is redundant, meaning that the two individual systems operate within one unit This is a safety argument detail: Due to each CPU having its own operating system, the whole unit is more diverse than a conventional system The bottom layer contains the STO switches and I/O drivers for the safety I/O 10

12 Here is information on the Status LEDs. The top LED (POWER) shows the power status. The second LED (RUN) tells which one of the three different modes is running. Flashing LED is a signal of a normal configuration mode. The third LED (STATUS/FAULT) shows the status of the safety functions. A red light means that a fault has occurred or that the drive is in configuration mode if the RUN LED is also blinking. A green light means that the safety functions are active (except SMS function), while the flashing of green means that a request for safety functions has ended (If system has a separate reset/acknowledge button, the flashing indicates that acknowledgement is still needed). The fourth LED (STO) represents the STO circuit status. The input and output LEDs are lit when they are at high state. LEDs are used for indication only, the LED information should not be blindly trusted. 11

13 This slide shows the FSO-11 module connections in more detail: X110, X111, X112, X113 and X114. X113 and X114 are identical connectors. Each is used as an individual channel (redundant architecture). There are eight inputs in total, that can be used as eight single inputs or as four redundant inputs, or as a combination of these. There is a total of six outputs, which can be used as six single outputs or as three redundant outputs, or as a combination. Both connectors also have one output for test pulses and two grounding pins. 12

14 The FSO-11 uses a speed estimator to implement safe speed and ramp monitoring without an encoder. A system is used which measures the output frequency from the drive from two separate channels. The first channel comes from the drive motor model giving a speed estimate. The second channel provides an estimate from the actual drive IGBT switching data. These signals are compared to each other: If too great variations exist between the two signals, a fault is triggered If no significant variations exist, this value is compared to the set speed limit This type of estimation method has some limitations: This method is designed only for applications where movement slows down when the drive is shut down. In highly dynamic situations, the load is unable to follow the motor control entirely. The motor control has to work accurately, i.e., a complete motor ID run is required during commissioning. 13

15 Briefly about responsibilities: the principle is that whoever places the machine in the market, the machine manufacturer or its representative, is responsible for the conformity of the complete machinery not ABB or any other component manufacturer. ABB is responsible exclusively for the safety functionality of the ABB manufactured safety component, when it is installed and commissioned as specified. 14

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