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FSO-21
ABB FSO-21 User Manual
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Intr
oducti
on t
o
the manual 29
Certifica
t
es
TÃœV Nord cert
ificat
e
for the FSO-
21 and
ACS880/DCS880 drive ser
ies can be found
in
ABB Library
. Check the validi
ty
o
f
the cert
ificat
e wi
th a speci
fic drive var
i
an
t from
the ABB Library
.
λ
s
Safe
fail
ure
rate
T
erm
/
Abbreviation
Description
28
30
Table of Contents
Default Chapter
5
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
17
Contents of this Chapter
17
Exclusion of Liability
17
Applicability
17
Compatible Products
18
ACS880 Drives and Option Modules
18
DCS880 Drives and Option Modules
18
Controller Stations
19
Tools
19
Supported Safety Functions
20
Target Audience
20
Purpose of the Manual
20
Contents
20
Recommended Reading
22
Terms and Abbreviations
22
Certificates
29
3 Safety Information and Considerations
31
Contents of this Chapter
31
Use of Safety Functions
31
Meeting the Requirements of the Machinery Directive
32
Responsibilities
32
Intentional Misuse
32
Safety-Related Parts
32
Limitations of Safe Torque off (STO) Function
32
Proof Testing
33
Safety Separation
33
ACS880 Drives with Separate Inverter and Supply Units
33
4 Overview
35
Contents of this Chapter
35
Intended Use of the FSO Module
35
System Description
36
FSO Module and Safety System Components
36
FSO Module Version Handling
37
Layout
38
Connections
39
Type Designation Label
39
Operational Characteristics
40
Response Times
40
FSO Diagnostics
41
I/O
41
Acknowledgement
42
Safety Encoders
43
Safe Position
44
Motor Speed Feedback
44
Overview of Safety Functions
48
Safe Torque off (STO)
48
Safe Stop 1 (SS1)
48
Safe Stop Emergency (SSE)
48
Safe Brake Control (SBC)
49
Safely-Limited Speed (SLS)
50
Variable Safely-Limited Speed (SLS)
50
Safe Maximum Speed (SMS)
50
Prevention of Unexpected Start-Up (POUS)
50
Safe Speed Monitoring (SSM)
50
Safe Direction (SDI)
51
Safe Acceleration Range (SAR)
51
5 Safety Functions
53
Contents of this Chapter
53
General
54
Safety Function Request
54
Acknowledgement Methods
55
DC Magnetization and Drive Start Modes
56
Ramp Monitoring
57
Safety Function Indications
58
FSO Modes
60
FSO States
60
Transitions between FSO Modes and States
61
Cascade
62
Mute Time Feature
64
Safe Torque off (STO)
67
STO Function
68
SBC after STO
71
SBC before STO
74
STO with Speed Limit Activated SBC
77
Safe Stop 1 (SS1)
79
SS1 with Time Monitoring (SS1-T)
80
SS1 with Ramp Monitoring (SS1-R)
84
SS1 with Speed Limit Activated SBC
88
SS1 with Speed Limit Activated SBC, SBC before STO
96
SS1 Ramp Functions When Drive Modulation Is Lost
104
Safe Stop Emergency (SSE)
106
SSE with Immediate STO
107
SSE with Immediate STO, SBC after STO
109
SSE with Immediate STO, SBC before STO
112
SSE with Immediate STO, with Speed Limit Activated SBC
115
SSE with Time Monitoring
116
SSE with Ramp Monitoring
120
SSE with Speed Limit Activated SBC
124
SSE with Speed Limit Activated SBC, SBC before STO
132
SSE When Drive Modulation Is Lost During Deceleration Ramp
139
Safely-Limited Speed (SLS)
140
SLS with Speed below Monitored Speed
141
SLS with Time Monitoring and Speed above Monitored Speed
143
SLS with Ramp Monitoring and Speed above Monitored Speed
145
SLS Reaction When Modulation Is Lost During Deceleration Ramp, with Ramp Monitoring
147
SLS Reaction When Modulation Is Lost During Deceleration Ramp, with Time Monitoring
157
FSO Boot Behavior with SLS Active
166
SLS Trip Limit Hits
167
Variable Safely-Limited Speed (SLS)
172
Variable SLS with Time Monitoring
173
Variable SLS with Ramp Monitoring
175
Safe Maximum Speed (SMS)
177
SMS Function, Version 1
178
SMS Function, Version 2
179
Prevention of Unexpected Start-Up (POUS)
180
Safe Speed Monitor (SSM)
182
SSM with a Safe Speed Estimate
184
Safe Direction (SDI)
186
SDI with Correct Rotation Direction
186
SDI with Time Monitoring
188
SDI with Ramp Monitoring
190
SDI Trip Limit Hits
192
Priorities between Safety Functions
193
Dependencies between Safety Functions
193
6 Profisafe
195
Contents of this Chapter
195
Introduction
195
System Description
196
Required Components
196
Tools
196
System Overview
197
Remote I/O Control
199
FSO Module Passivation
199
Profisafe Description
200
Profisafe Message Format
200
FSO Profisafe Profiles
201
FSO Module Modes and States
212
Profisafe Response Time
224
Profisafe Watchdog Time
226
Installation
228
Configuration
229
Configuring the FB Module
229
Configuring the FSO Module
230
Configuring the Safety PLC
231
Downloading the GSD File
231
Configuring the ABB AC500-S Safety PLC
231
Configuring the Siemens SIMATIC Fail-Safe S7 PLC
249
Configuring Siemens S7-1200 PLC with TIA14
264
Fault Tracing
280
Reading Diagnostic Messages
280
Diagnostic Messages Related to F-Parameters
283
Typical Communication Errors
284
7 Planning for Installation
287
Contents of this Chapter
287
Requirements for Designers and Installers
287
Mechanical Installation
287
Installation Site
287
Electrical Installation
288
General Requirements
288
Connections
288
STO Cable and Data Cable between FSO Module and Drive
289
Power Supply Connection/Cables
289
Power Supply for the FSE Module and Safety Encoders
289
Ensuring the EMC Compatibility
289
Selecting Control Cables
290
Routing the Cables
290
Standard Function and Wiring Examples
291
8 Installation
295
Contents of this Chapter
295
Unpacking
296
Examining the Delivery
296
Mechanical Installation
297
Installing the Module Onto a BCU Control Unit
297
Installing the Module Onto a ZCU Control Unit
298
Electrical Installation
299
Terminals
299
Connection Procedure
300
9 Installation Checklists
305
Contents of this Chapter
305
Checklists
305
10 Configuration
307
Contents of this Chapter
307
Competence
307
Password
307
Configuring the FSO Module
308
Overview - Safety System Configuring Process
308
FSO Configuring Procedure
310
Configuring General Settings
312
How to Configure General Settings
312
Configuring the Safety Encoder Interface
313
How to Configure the Safety Encoder Interface
313
Diagnostics of FSE-31 Encoder Interface Module
315
Disabling the Safety Encoder Interface
316
Configuring the FSO for FSE or Encoder Failure Situations
317
Encoder Diagnostics Failure Reaction
317
Configuring the Safety Fieldbus Communication
318
How to Configure the Safety Communication with Profisafe
318
Configuring I/O
319
How to Configure I/O
319
How to Configure a Cascaded System
322
How to Configure Safety Relays
326
Configuring SBC
327
How to Configure the SBC in the STO Function
329
How to Configure the SBC in the SS1 Function
330
Configuring STO
331
How to Configure STO
331
How to Configure SBC after STO
333
How to Configure SBC before STO
335
How to Configure STO with Speed Limit Activated SBC
337
Configuring SS1
340
How to Configure SS1 with Time Monitoring (SS1-T)
340
How to Configure SS1 with Ramp Monitoring (SS1-R)
342
How to Configure SS1 with Speed Limit Activated SBC
343
How to Configure SS1 with Speed Limit Activated SBC, SBC before STO
347
Related Safety Functions
350
Configuring SSE
351
How to Configure SSE with Immediate STO
351
How to Configure SSE with Immediate STO, SBC after or before STO
353
How to Configure SSE with Immediate STO with Speed Limit Activated SBC
353
How to Configure SSE with Time Monitoring
354
How to Configure SSE with Ramp Monitoring
355
How to Configure SSE with Speed Limit Activated SBC
356
How to Configure SSE with Speed Limit Activated SBC, SBC before STO
360
Related Safety Functions
360
Configuring SAR
361
How to Configure Sarn
361
Configuring SLS
362
How to Configure Slsn with Time Monitoring
362
How to Configure Slsn with Ramp Monitoring
364
Related Safety Functions
365
Configuring Variable SLS
366
How to Configure Variable SLS with Time Monitoring
366
How to Configure Variable SLS with Ramp Monitoring
368
Defining the Scaled SLS4 Limit and SLS4 Trip Limits
370
Related Safety Functions
373
Configuring SMS
374
How to Configure SMS, Version 1
374
How to Configure SMS, Version 2
375
Related Safety Functions
375
Configuring POUS
376
How to Configure POUS
376
How to Configure SLS Function Behavior When Drive Modulation Is Lost
376
Tion Ramp
377
Tion Ramp
383
Configuring SSM
387
How to Configure SSM
388
Configuring SDI
389
How to Configure SDI with Time Monitoring
390
How to Configure SDI with Ramp Monitoring
391
Related Safety Functions
392
Configuring Mute Times
393
How to Determine Values for Mute Time Parameters
393
How to Configure Limit Hit Situations
394
How to Configure Mute Time for Zero Speed Detection
397
How to Configure Mute Time for SBC Speed Limit Detection
398
How to Configure Mute Time for Monitoring Start
399
11 FSO-21 Parameters
401
Contents of this Chapter
401
Status and Control Words
449
12 Start-Up
455
Contents of this Chapter
455
Safety Considerations
455
Checks
456
13 Verification and Validation
457
Contents of this Chapter
457
Verifying the Achieved SIL/PL Level
457
Purpose of the Validation Testing
457
Preconditions for Validation Testing
458
Validation Procedure
458
General
458
Validation Test Reports
459
Competence
459
Tools
459
Validation of the Profisafe Connection
460
Validation of the Safety Encoder Interface
461
Validation of Safety Functions
464
Validation of Redundant Inputs
464
Validation of Safety I/O's
465
Validation of the General Settings
465
Validation of the STO Function
466
Validation of the SBC Function
468
Validation of the SSE Function
470
Validation of the SS1 Function
473
Validation of the SLS Functions
475
Validation of the Variable SLS Function
477
Validation of the SMS Functions
479
Validation of the POUS Function
481
Validation of the SSM Functions
482
Validation of the SDI Function
483
Validation of the Cascaded Safety Function
486
Proof Test Intervals During Operation
487
Residual Risks
487
14 Fault Tracing
489
Contents of this Chapter
489
Status Leds
489
Event Types
490
Event Code Decoding with Drive Composer Pro Tool
490
Faults, Warnings and Events
491
User-Selectable Events for Function Requests
501
User-Selectable Events for Limit Hits and Special Events
501
User-Selectable Events for Safety Fieldbus Failures
504
Auxiliary Codes
504
FSO Recovery
504
External Fault
504
Internal Fault
505
Reporting Problems and Failures
505
15 Maintenance
507
Contents of this Chapter
507
Planning
507
Tools
507
Component Replacement in the Safety Circuit
508
Before Component Replacement
508
Replacing the FSO Module
508
Reinstalling the FSO Module to Another Drive
509
Replacing the Control Unit of the Drive
509
Replacing the Memory Unit or Updating the Firmware of the Drive
509
Replacing a Power Unit, or Its Circuit Boards or Wirings
509
Replacing the FB Module in Profisafe Network
510
Replacing the FSE Module
510
Replacing the Safety Encoder
510
Start-Up and Validation Test
510
Factory Reset
511
Drive Control Board Boot
512
Updates
512
Proof Tests
512
Decommissioning
512
16 Technical Data
515
Contents of this Chapter
515
Electrical Data
515
Profisafe and Related Network Devices
515
Control Connection Data
516
Terminal and Cable Entry Data for the Control Cables
516
STO Cable and Data Cable between FSO Module and Drive
517
Tightening Torques
517
Size and Weight
517
Cooling
517
Compatible Motor Types
518
Speed Estimation
518
Ambient Conditions
518
Safety Functions
519
Safety Data
520
General
520
Basic Safety Data
522
Pulse Encoder Interface Module
523
FSO Safety Calculations Guide (Without Profisafe)
524
FSO Safety Calculations Guide (with Profisafe)
529
Safety Data for some Typical Configurations
529
Relevant Failure Modes
531
Response Times
532
Ordering Information
534
Related Standards and Directives
535
17 Dimension Drawings
537
Further Information
539
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ABB FSO-21 Specifications
General
Brand
ABB
Model
FSO-21
Category
Control Unit
Language
English
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