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ABB FSO-21 User Manual

ABB FSO-21
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Overview 37
from an FSO internal fault. Some safety functions can be permanently active. If the
drive does not fulfill the commands of the FSO, the FSO stops the drive modulation
using the Safe torque off (STO) function.
If the drive is connected to a safety PLC, the safety of the fieldbus communication
can be secured with the PROFIsafe over PROFINET technology. The safety PLC is
connected to the FB module, which communicates with the FSO module. For more
information, see chapter PROFIsafe.
If a pulse encoder is used in the safety system, it is connected to the FSE-31 module,
which communicates with the drive and the FSO-21 module.
Safety functions supported by the FSO module are presented in chapter Safety
functions.
FSO module version handling
To ensure backward and forward compatibility with the ACS880/DCS880 drives, the
FSO-21 module has a version handling system. Both the FSO module and the
ACS880/DCS880 drive firmware must support the used safety functions.
You can always replace the FSO-21 module with a newer revision and use the same
configuration file with the new revision. If you replace an FSO-12 module with an
FSO-21 module, you have to re-configure the FSO module and safety functions.
Each time you make any changes in the safety system, you must do the acceptance
test to each safety function using the checklists described in chapter Verification and
validation.
Note: Due to an update in functionality related to a situation where drive modulation
is lost when SLS function is active, it is recommended to update all FSO modules to
revision H (or later).
Each new revision of the FSO-21 module supports all or most functions of previous
FSO-21 module revisions and it can be used together with previous
ACS880/DCS880 drive firmware versions. In addition, previous FSO-21 module
revisions can be used together with new ACS880/DCS880 drive firmware versions. In
this case, the drive supports only the functions of the previous FSO-21 module
revision. For more information on product compatibility, see section Compatible
products on page 18.
In Drive composer pro PC tool, each safety function and parameter group has a
version parameter. With these parameters, the user selects the desired versions.
Only the versions that are supported by both the drive firmware and the FSO module
are shown in the Drive composer pro.

Table of Contents

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ABB FSO-21 Specifications

General IconGeneral
BrandABB
ModelFSO-21
CategoryControl Unit
LanguageEnglish

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.

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

Planning for installation

Installation

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 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.

Parameters

Start-up

Verification and validation

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.

Fault tracing

Maintenance

Component replacement in the safety circuit

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

Factory reset

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

Technical data

Safety functions

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

Basic safety data

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

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