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

Transcription

1 Welcome to the safety functions configuration training module for ACS880 Cabinet-built industrial drives. 1

2 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 FSO configuration, and change the emergency stop function stop category from 0 to 1. 2

3 The FSO safety module allows implementing integrated safety functionalities and provides complete safety solutions. The FSO has several digital safety inputs and outputs, which are used to make the safety options 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 FSO module to the drive. Also the parameter lists related to the pre-configured safety options will be presented. For the FSO-12 module the option code is +Q973 and for the FSO-21 +Q972. 3

4 There is one important difference between the FSO modules: The FSO-21 module offers a 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 motor speed for functional safety purposes. 4

5 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 terminal numbers are fixed to the safety option: Here is an example of a safety options combination (+Q973 and +Q978). Test pulses and grounds are always bridged in X68. The actual delivery might also include other external customer terminals such as X951 and X957. 5

6 The pulse encoder interface module FSE-31 is intended to be used for functional safety purposes with FSO-21 safety functions module. The same pulse encoder interface is also used for motor control. The FSE-31 communicates with the ACS880 inverter unit and the FSO-21 via a control unit. The FSE module supports a differential safety encoder. The FSE encoder interface mounts on slot 2 by default. The interface uses same external power source as the FSO-21 module and it requires a differential safety encoder for the motor. 6

7 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 in use. The pins are allocated from top to bottom in ascending order. The 24 volt output to differential safety encoder is connected to pin 1, signal ground to pin 2 and signal channels to pins 3 to 8. Encoder cable shield is connected to pin 9. The Z-channels (7 and 8) are in use with the FSE module. (The FSE module requires an external 24 volt input power source, connector X81.) 7

8 Configuring the FSE pulse encoder. FSO parameters from groups 91 and 92 on white background are common both with FSO-21 and inverter unit firmware. These parameters are set to the inverter unit during control unit reboot. If the user has to reconfigure the parameters on white background, they have to be set via the FSO module. (E.g. during commissioning, the FSE parameters have to be set via the FSO module.) The parameters on blue background exist only in the FSO-21. E.g. encoder count ( ) and fault reaction function (S_ENCGEN.11) from the FSE-31 failure are defined with these parameters. In addition to these functions, the parameters on green background are also set at the factory. The green parameters exist only in the inverter unit firmware and are set for encoder cable fault diagnostics. 8

9 Here are listed the safety options for the ACS880 cabinet-built drives. The FSO safety options module is included in each option with code +Q973 for the FSO-12 and +Q972 for the FSO-21. It is possible to combine safety options together to establish required functionalities. 9

10 Here is an illustration of the FSO option +Q979, Emergency stop with STO, and its components. In this example the control unit, the FSO and the FSE modules must be powered with an external power supply to work properly. Wire harnesses are installed at the factory. The user may not change any component or wirings without performing verification and validation afterwards to the system. With option +Q979 emergency stop is not connected to the main contactor, i.e. the DClink 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. 10

11 Here is an example of an emergency stop procedure in single drives. (Activation and deactivation) The drive is running at first, test pulses are functioning and their indication LEDs are lit in the FSO module. As the user pushes the emergency stop button, voltage to digital inputs X113.1 and X114.1 goes down and the FSO starts controlling the drive bringing it to a Safe torque off ( STO) state. The STO LED also activates in the FSO module. When the user lifts up the emergency button and resets the system, the FSO receives an acknowledgement signal that the emergency stop has been recognized and drive is reset. 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 are missing or the fault LED is lit, there is a mistake in the input wiring. If Fault or STO LEDs are lit there might be also problem in parameterization. 11

12 Here is shown Emergency stop option +Q979 basic function. Active signals are shown with red and disabled signals with dashed black line. In this state the drive is modulating and the motor is running. Test pulses are received in the digital input terminals (DI) X113.1 and X114.1 and STO connector receives the active signals (high) from the FSO. 12

13 When the user activates the emergency stop, voltage goes down in digital inputs X113.1 and X The FSO disconnects the STO supply and the STO signals fall down in the inverter module. Simultaneously the reset pilot light switches on to indicate emergency stop situation. As a result the drive modulation is stopped and the motor is cut off from power supply. To restore the drive to run state, the user must pull up the emergency stop button and press the reset button. Depending on the parameter 31.22, the drive might need to be reset. 13

14 Here are the +Q979 option connections made from the FSO module to the customer terminal. The parameters on green background are preconfigured by ABB and the parameters on yellow background can be adjusted according to the customers needs. 14

15 Here is an illustration of the single drive option +Q978 Emergency stop with Main contactor (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. 15

16 Here is the connection diagram of the Emergency stop option +Q978, which opens the main contactor (MC) or main circuit breaker (MCB). (Active signals are shown with red and disabled signals with dashed black line.) In the beginning the drive is modulating and the motor is running. Test pulses are received in the digital input terminals X113.1 and X The STO connector gets active (high) signals from the FSO. Compared to the previously presented option +Q979, in this option additional inputs and outputs from the FSO are used to control and supervise a breaker. The standard closed supervision contact of the device is wired to DI X113.2, which receives the test pulse signal when the device is in open position. When the drive is running, the device is closed and input voltage is down. The supply switching device is controlled by a safety relay, which is wired to DO X In the picture the relay output is active, safety relay is energized and the main contactor is closed. 16

17 When the user activates the emergency stop, DI X113.1 and DI X114.1 stop receiving the test pulses. The FSO disconnects the STO supply and STO signals go low in inverter module. At the same time reset pilot light DO X114.7 switches on indicating emergency stop situation. Additionally the FSO deactivates the D O X114.9 and safety relay deenergizes, which opens the supply disconnection device. As a result drive modulation is stopped, supply is disconnected and motor stops receiving power. To restore the drive to run state, user must pull the emergency stop button up and press the reset button. Depending on the parameter 31.22, drive might need to be reset. 17

18 Here are the +Q978 option connections from the FSO module and the related parameters. Parameters on green background have been preconfigured by ABB and parameters on yellow background can be adjusted according to the customers needs. 18

19 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. 19

20 The drive is modulating and motor is running. Test pulses are received in the DI terminals X113.3 and X

21 The POUS function should be used after the user has stopped the drive. Now drive modulation is stopped and motor is not powered. The POUS switch is disengaged and the digital inputs X113.3 and X114.3 contacts are disconnected from the test pulses. The POUS pilot light switches on simultaneously to indicate POUS activation. Inverter side is not disconnected from the supply. To restore the drive to run state the user must turn the POUS switch back on. 21

22 Here are the multidrive POUS connections from the FSO and the related parameters. Parameters on green background are preconfigured by ABB and parameters on yellow background can be adjusted according to the customers needs. 22

23 The drive is modulating and motor is running. Test pulses are received in the DI terminals X113.3 and X

24 Here are the FSO-21 parameters related to SLS function configuration with option +Q965 for ACS880 cabinet-built single drives. The SLS inputs and one pulsed output are configured for SLS1 function. Option +Q965 includes also safe speed monitoring function, SSM. The SSM configuration is presented later with option +Q965 for ACS880 multidrives. (Parameters on green background are preconfigured by ABB and parameters on yellow background can be adjusted according to the customers needs.) 24

25 In multidrive applications, safety functions can be implemented by linking multiple FSO modules. This slide illustrates the multidrives emergency stop option +Q979 where multiple FSOs are grouped together to create an emergency stop network. The FSO inputs are powered with an external 24 V supply which is disconnected with a safety relay. As the emergency stop button is pushed, the FSOs do not receive signal in DI X113.1 and DI X Then STO is activated for each inverter unit. If the customer order consist of several line-ups, the emergency stop network is galvanically isolated between the line-ups. 25

26 Here are the multidrive emergency stop option connections from the FSO and the related parameters. (Parameters on green background are preconfigured by ABB and parameters on yellow background can be adjusted according to the customers needs.) 26

27 The following video demonstrates the configuration of the Emergency stop option +Q979 for multidrives. Ramp monitoring is chosen as the monitoring method. 27

28 The parameter values used in this video are only examples. All the motor specific values and delay times depend on application and motors used. In this example the final safety configuration is done off-line to the pre-configured safety file delivered to the customer by ABB. The pre-configured safety file is already uploaded to the PC from the FSO. The modifications to safety parameter settings are done with Drive composer PC tool. The modified safety file must be downloaded to the FSO after these parameter settings are done. 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 drive under 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. SAR1 parameters are set for ramp monitoring. Target ramp slope is set. Speed scaling and motor nominal values are set according to the motor. Scroll down to see other parameters. Trancient mute time is set. Zero speed limit is set to a suitable value for STO activation after ramp stop. The FSO STO input A is set to none. Make sure not to configure same digital inputs for FSO STO function and SS1 function. If both functions are configured to same 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 28

29 input A, we choose the input that was previously in use in STO function. SS1 input B is not in use and is set to none. In this example monitoring method is set to ramp. Since there are no SS1 outputs, they are set to none. Next we set the SAR ramp range and ramp limits for the ramp monitoring. Maximum ramp slope is set to higher value than the target ramp slope. Minimum ramp slope is not monitored 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 the inverter unit: Open the safety file and click download to FSO. At this point the PC tool will ask for a password. When the file is downloaded successfully, the new safety configuration is ready for use. 28

30 Here is an illustration of the Prevention of unexpected start-up (POUS) option +Q950 in multidrives. The POUS option can be used in multidrives in a similar way as in single drives. In multidrives, in addition to the FSO single setup, several inverter units can be grouped together 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 the POUS switch. The POUS pilot light switches on and the STO for the corresponding inverter unit is activated. At the same time the followers receive the same POUS request through the master s DO X113.9 and DO X114.9 and they activate the STO for the corresponding inverter units as well. If the POUS is activated when the motor is running, a coast stop is executed. 29

31 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 to change parameters at the site for this configuration.) 30

32 Here is illustrated the Safely-limited speed (SLS) option +Q965/+Q966 in multidrives. The SLS supervises and controls that the motor does not exceed the speed configured by the FSO safety parameter. Every control unit has its own SLS switch and an indication output. The SLS networks are configured at the factory. All the FSOs individually supervise and control that the motors speeds are below the limit defined by the FSOs parameters. 31

33 Here is a multidrive example of the Safely-limited speed (SLS) FSO parameters. The SLS1 function is used in the FSO module. One redundant SLS input and one pulsed output are configured for the SLS function. SLS network is wired at ABB factory when SLS request is intended to activate safely-limited speed in more than one inverter unit at the same time. In that case the SLS is activated with one 24 V powered switch for all the inverter units 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 yellow background can be adjusted according to the customers needs.) 32

34 Here are the safe speed monitoring (SSM) connections and the FSO parameters of this configuration for cabinet built drives with option codes +Q965 and +Q966 with FSO-21 module. One pulsed output is configured for the SSM and the safety function is configured to be permanently on. The parameter settings for the SSM function with option +Q965 with ACS880 cabinet-built single drives are similar as with multidrives shown here. 33

35 Here is an illustration of the PROFIsafe +Q982 option. This example consists of the following components: ACS880 drive FENA-21 fieldbus module FSO safety functions module Safety master programmable logic controller (PLC) supporting PFOFIsafe The option does not include PROFINET cabling to connect the drives together. 34

36 Here is an illustration of the PROFINET network, established between inverters. The Ethernet switches are PROFINET certified and they include important quality features such as media redundancy protocol (MRP). The FENA-21s fieldbus modules are connected to the switches. In basic design, in inverters R1i to R5i, the FENA-21 modules are chained together to save switch ports. The cabling is also PROFINET certified. The green color differentiates it from basic Ethernet cable. The green cable is used inside the line-up construction. In this picture the customer connection with optical cable is shown with black color. 35

37 It is highly recommended to always save the latest version of the safety configuration file in addition to the pre-configuration file delivered by ABB. The FSO module must be completely configured in the case of Replacing the FSO module with a new one Updating the firmware in the inverter units FSO factory reset Re-configuring can be done by downloading the existing safety file with application specific safety parameter values. 36

38 Here is a summary of the discussed topics. 37

39 38