ABB FSO-21 User Manual

Safety information and considerations 33
of the system (including drive and the motor) can only be carried out after a proper
isolating procedure, which must be obeyed to make sure that the maintained part of
the system is properly isolated.
 Proof testing
Periodic proof testing of, for example, electromechanical parts of the safety system
may be required in order to maintain the claimed SIL / PL level of the system. In this
case proof testing must be taken into consideration in the safety calculations and it
must be properly documented in the user documentation. Proof testing has to be
verified in the acceptance testing during the commissioning phase.
The FSO module itself does not require periodic proof testing.
External contactors, relays and mechanical actuators must be sized correctly for
safety use as the automatic diagnostics only monitors the electrical connections; the
mechanical final elements like brakes are not diagnosed.
Failure of a mechanical actuator, for example a brake, could lead up to an undetected
fault, and a possible loss of the load control.
 Safety separation
The FSO module and the drive Safe torque off (STO) channel/function are safety
relevant, and the rest of the drive is considered as not safety relevant, for example,
the drive regular I/O cannot be used for requesting safety functions on the FSO.
WARNING! The Safe torque off function does not disconnect the voltage of the
main and auxiliary circuits from the drive. Do not do maintenance work on the
electrical parts of the drive or the motor before you isolate the drive system
from the main supply, from rotating permanent magnet motors, from rotating
motors equipped with sine filters and from all dangerous external voltages.
Note: The Safe torque off function can be used for stopping the drive in the
operational mode. If a running drive is stopped by using the STO function, the drive
stops by coasting.
 ACS880 drives with separate inverter and supply units
In ACS880 drives with separate inverter, supply and brake units, the FSO module is
connected to the inverter unit(s). It cannot be connected to supply or brake units.

ABB FSO-21 Specifications

General

Brand	ABB
Model	FSO-21
Category	Control Unit
Language	English

Summary

Safety instructions

Electrical safety precautions

Electrical safety precautions for personnel working on drives, motor cables, or motors.

Introduction to the manual

Supported safety functions

Details safety functions supported by FSO-21 module per EN/IEC 61800-5-2.

Overview

Intended use of the FSO module

FSO-21 adds safety functionality to drives, supporting PROFIsafe and safety encoders.

Overview of safety functions

Safe torque off (STO)

Activates drive STO function to bring machine to a no-torque state by stopping motor.

Safe stop 1 (SS1)

Safely stops motor by ramping down speed to zero, monitored by time or ramp method.

Safe stop emergency (SSE)

Stops motor safely by coasting or ramping down, similar to STO or SS1.

Safe brake control (SBC)

Provides safe output for external safety brakes, always combined with drive STO.

Safely-limited speed (SLS)

Prevents motor exceeding user-defined speed limits; activates SSE if trip limit is reached.

Variable Safely-limited speed (SLS)

Allows scaling of SLS limits via safety PLC using PROFIsafe.

Safe maximum speed (SMS)

Protects machine from high speeds/frequencies; can be permanently on or off.

Prevention of unexpected start-up (POUS)

Prevents machine from starting unexpectedly by activating drive STO.

Safe speed monitor (SSM)

Provides safe output signal for motor speed within user-defined limits.

Safe direction (SDI)

Monitors correct motor rotation; activates SSE if forbidden direction is exceeded.

Safe acceleration range (SAR)

Provides safe deceleration ramp monitoring for other safety functions.

Safety functions

Cascade

Planning for installation

Installation

Mechanical installation

Electrical installation

Connection procedure

Configuration

Configuring the FSO module

Overview of safety system configuration process: risk assessment, requirements, design, validation.

FSO configuring procedure

Steps for setting FSO parameters using Drive composer pro PC tool.

Configuring general settings

Configuring the safety encoder interface

Configuring the safety fieldbus communication

Configuring I/O

Configuring SBC

Configuring SBC function with STO, SSE, SS1, considering delays and speed limits.

How to configure the SBC in the STO function

Setting SBC usage, delay, and speed limit parameters for SBC in STO function.

Configuring STO

Setting FSO parameters for STO function: input, acknowledgement, output configurations.

How to configure SS1 with time monitoring (SS1-t)

Setting SS1 parameters for time monitoring: activation, delays, acknowledgement, outputs.

How to configure SS1 with ramp monitoring (SS1-r)

Setting SS1 parameters for ramp monitoring: activation, SAR1, acknowledgement, outputs.

How to configure SSE with immediate STO

Configuring SSE with immediate STO: activation, acknowledgement, and output settings.

How to configure SSE with ramp monitoring

Configuring SSE with ramp monitoring: activation, SAR0, acknowledgement, outputs.

Configuring SLS

Setting FSO parameters for SLS functions (SLS1-4, Variable SLS): limits and trip limits.

How to configure SLSn with time monitoring

Configuring SLSn with time monitoring: activation, delay, acknowledgement, outputs.

How to configure Variable SLS with time monitoring

Configuring Variable SLS with time monitoring: activation, acknowledgement, delays, outputs.

Configuring SMS

Configuring SMS function (version 1 or 2) for protection against high speeds/frequencies.

Configuring POUS

Configuring POUS function to prevent unexpected start-up: activation, acknowledgement, inputs, delay, outputs.

Configuring SSM

Configuring SSM function for monitoring motor speed between user-defined limits.

Configuring SDI

Configuring SDI function to monitor correct motor rotation, requiring an encoder.

Configuring mute times

How to configure limit hit situations

Parameters

FSO-21 parameters

Start-up

Safety considerations

Verification and validation

Validation procedure

Validation of the PROFIsafe connection

Validation of the safety encoder interface

Validation of the SBC function

Validates SBC function, ensuring correct wiring and configuration for delayed brake and speed limit activated brake.

Validation of the SSE function

Validates SSE function: immediate STO, emergency ramp with safe speed estimate or encoder.

Validation of the SS1 function

Validates SS1 function: inputs, SAR1/time monitoring settings, acknowledgement, indications.

Validation of the SLS functions

Validates SLS functions (SLS1-4): inputs, functionality, acknowledgement, indications for ramp/time monitoring.

Validation of the variable SLS function

Validates variable SLS function: PLC scaling, inputs, acknowledgement, outputs.

Validation of the SMS functions

Validates SMS functions (version 1 and 2): activation, limits, SSE function configuration.

Validation of the POUS function

Validates POUS function: inputs, outputs, activation, acknowledgement, functionality.

Validation of the SSM functions

Validates SSM functions (SSM1-4): inputs, outputs, activation, limits.

Validation of the SDI function

Validates SDI functions: inputs, configuration, tolerance limits, acknowledgement for ramp/time monitoring.

Validation of the cascaded safety function

Fault tracing

Faults, warnings and events

FSO recovery

Maintenance

Component replacement in the safety circuit

Instructions for replacing FSO/FSE modules, control units, or FB modules, ensuring safety during process.

Replacing the FSO module

Replacing the FB module in PROFIsafe network

Start-up and validation test

Factory reset

Resets FSO to factory settings; requires reconfiguration. Backup safety file before reset.

Technical data

Electrical data

Safety functions

Categorizes safety functions into Stopping and Speed-related, listing specific functions.

Stopping functions

Speed-related functions

POUS

Prevention of unexpected start-up function.

Safety data

Determines SIL/PL capability by adding failure rates of components.

PROFIsafe

Subsystem for PROFIsafe connection reliability, handled by FSO module via FENA/FPNO.

FSO safety calculations guide (without PROFIsafe)

FSO safety calculations guide (with PROFIsafe)

Basic safety data

Lists FSO-21 safety data related to IEC 61508, EN ISO 13849-1, IEC 61511, EN IEC 62061.