ABB Industrial Drives Application Guide ACS800-01/U1/04 .
ABB industrial drivesApplication 104/104LCSafe torque off function ( Q967)
List of related manualsSingle drive and drive modules hardware manualsACS800-01/U1 Hardware ManualACS800-04/04M/U4 Hardware Manual (45 to 560 kW)ACS800-04 Drive Modules Hardware Manual (0.55 to 200 kW)ACS800-11/U11 Hardware ManualACS800-14 Frequency Converter Modules SupplementACS800-31/U31 Hardware ManualCode 83678833AFE684589863AFE64671006Air-cooled multidrive modules manualsACS800 Multidrive and Multidrive Modules Safety Instructions3AFE64760432ACS800 Multidrive and Multidrive Modules Planning the Electrical 3AFE64783742InstallationACS800-104 Inverter Modules Hardware Manual3AFE64809032Liquid-cooled multidrive modules manualsACS800 Liquid-cooled Multidrive and Multidrive Modules SafetyInstructionsACS800 Liquid-cooled Multidrive and Multidrive ModulesPlanning the Electrical InstallationACS800-104LC Inverter Modules (1.5. to 2240 kW) Firmware manualsACS800 standard control program firmware manualACS800 system control program firmware manualApplicable control program firmware manuals3AFE645275923AFE64670646Option manuals and general safety guidesFunctional safety; Technical guide No. 10Safety and functional safety; A general guideABB Safety information and solutionsManuals and quick guides for I/O extension modules, fieldbusadapters, yYou can find manuals and other product documents in PDF format on the Internet. See sectionDocument library on the Internet on the inside of the back cover. For manuals not available in theDocument library, contact your local ABB representative.
Application 104/104LCSafe torque off function ( Q967)Table of contents3. Installation4. Start-up and use 2015 ABB Oy. All Rights Reserved.3AUA0000063373 Rev HENEFFECTIVE: 2015-03-12
5Table of contents1. Introduction to the manualContents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Applicability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Target audience . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7778892. Option descriptionContents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Operation principle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .STO status indications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .STO function activation and indication response times . . . . . . . . . . . . . . . . . . . . . . . . .Module response times only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Response times with typical safety relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .111112131414143. InstallationContents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Supply voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .STO input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Activation switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Cable types and lengths . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Cable between STO activation switch and drive/inverter module or ASTO board .Cable between ASTO board and drive/inverter module . . . . . . . . . . . . . . . . . . . .Example wiring diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .STO connections without safety relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Connecting the STO activation switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Frame sizes R2 to R6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Frame sizes R7 and R8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Frame sizes R2i to R4i . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Frame size R5i . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Frame size R7i . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Frame size R8i . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Liquid-cooled modules of frame sizes R7i and R8i . . . . . . . . . . . . . . . . . . . . . . . .STO connections with safety relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Frame sizes R2 to R6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Frame sizes R7 and R8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Frame sizes R2i to R4i . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Frame size R5i . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Frame size R7i . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Frame size R8i . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Connecting several drive/inverter modules or inverter units to one safety relay . 728
64. Start-up and useContents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Start-up and acceptance test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Competence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Acceptance test reports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Acceptance test procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2929293030315. Maintenance and fault tracingContents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Proof test interval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Competence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Fault tracing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Warning messages generated by the drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Fault messages generated by the drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .333333343434346. Technical dataContents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .STO components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .ASTO-11/21 board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .ASTO-11 and ASTO-21 board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .ASTO-11 board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .ASTO board according to frame size of the module . . . . . . . . . . . . . . . . . . . . . . .Dimensions of the ASTO board with enclosure . . . . . . . . . . . . . . . . . . . . . . . . . .STO safety relay type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Push-button to be used with emergency stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Switch to be used with Prevention of unexpected start-up functionimplemented with STO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Safety data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .STO in ACS800 drives and inverter modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Multiples of frame size R8i . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Related standards and directives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Compliance with the European Machinery Directive . . . . . . . . . . . . . . . . . . . . . . . . . . .TÜV certificate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Declarations of Conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3535353535363637373737373839394041Further informationProduct and service inquiries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Product training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Providing feedback on ABB Drives manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Document library on the Internet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43434343
Introduction to the manual 71Introduction to the manualContents of this chapterThis chapter describes the manual in short and gives some general information for thereader.ApplicabilityThe manual applies to the ACS800-01/04/04LC/04M/11/14/31/104/104LC andACS800-U1/U4/U11/U31 drives and inverter modules which have the option Q967:Safe torque off (STO).Safety instructionsOnly a qualified electrician who has appropriate knowledge on functional, machine andprocess safety is allowed to install, start up and maintain the safety circuit.WARNING! The Safe torque off function does not disconnect the voltage of themain and auxiliary circuits from the inverter. Therefore maintenance work onelectrical parts of the inverter or the motor can only be carried out after isolatingthe inverter from the main supply.WARNING! The Safe torque off functionality is only achieved, when the ASTOboard is installed on the inverter module. True Safe torque off functionality is notachieved, if the option board is installed on other types of modules, such as thesupply unit or the brake unit.
8 Introduction to the manualWARNING! (With permanent magnet motors only) In case of a multiple IGBTpower semiconductor failure, the inverter system can produce an alignmenttorque which maximally rotates the motor shaft by 180/p degrees regardless ofthe activation of the Safe torque off function. p denotes the number of pole pairs.WARNING! Read and obey all safety instructions in the drive hardware manual.If you ignore them, injury or death, or damage to the equipment can occur.This manual does not repeat the complete safety instructions of the drive but it onlyincludes the instructions related to the scope of this manual.Target audienceThis manual is intended for people who install, start up, use and service the drive safetyoption. Read the manual before working on the drive. You are expected to know thefundamentals of electricity, wiring, electrical components, electrical schematic symbols,and functional safety.ContentsThe chapters of this manual are briefly described below.Introduction to the manual (this chapter) introduces this manual and gives safetyinstructions.Option description describes the Safe torque off (STO) function of the drive and invertermodules and lists the indications and response times of the Safe torque off function.Installation describes the installation procedure, wiring and allowed cable type of the Safetorque off function.Start-up and use contains the start-up and acceptance test procedure for the Safe torqueoff function and gives instructions for its use.Maintenance and fault tracing describes the maintenance procedure, requiredcompetence for maintenance personnel and fault tracing information for the Safe torqueoff function.Technical data contains the technical details of the ASTO-11 and ASTO-21 boards, thesafety data for the STO and example information of safety relays, safety logic andactivation switches. It also lists the related standards and directives, and contains the TÜVcertificate and declarations of conformity with the European Machinery Directive.
Introduction to the manual 9AbbreviationsAbbreviations used in this manual are listed below.Abbr.ReferenceASTOCat.DescriptionSafe torque off boardEN ISO 13849-1Category. Classification of the safety-related parts of a control system inrespect of their resistance to faults and their subsequent behavior in thefault condition, and which is achieved by the structural arrangement ofthe parts, fault detection and/or by their reliability. The categories are: B,1, 2, 3 and 4.CCFEN ISO 13849-1Common cause failure (%)DCEN ISO 13849-1Diagnostic coverageHFTIEC 61508Hardware fault toleranceMTTFdEN ISO 13849-1Mean time to dangerous failure: (The total number of life units) / (thenumber of dangerous, undetected failures) during a particularmeasurement interval under stated conditions.PFDIEC 61508Probability of failure on demandPFHIEC 61508Probability of dangerous failures per hourPLEN ISO 13849-1Performance level. Levels a e correspond to SIL.SCIEC 61508Systematic capabilitySFFIEC 61508Safe failure fraction (%)SILIEC 61508Safety integrity level (1 3)SILCLIEC/EN 62061Maximum SIL (level 1 3) that can be claimed for a safety function orsubsystemSS1IEC/EN 61800-5-2Safe stop 1STOIEC/EN 61800-5-2Safe torque offT1IEC 61508Proof test interval. T1 is a parameter used to define the probabilisticfailure rate (PFH or PFD) for the safety function or subsystem.Performing a proof test at a maximum interval of T1 is required to keepthe SIL capability valid. The same interval must be followed to keep thePL capability (EN ISO 13849) valid. Note that any T1 values statedcannot be regarded as a guarantee or warranty. See also section Prooftest interval on page 33.
10 Introduction to the manual
Option description 112Option descriptionContents of this chapterThis chapter describes the Safe torque off (STO) function of the drive and invertermodules and lists the indications and response times of the Safe torque off function.DescriptionThe Safe torque off function can be used, for example, to construct safety or supervisioncircuits that stop the inverter in case of danger (such as an emergency stop circuit).Another possible application is a prevention of unexpected start-up function that enablesshort-time maintenance operations like cleaning or work on non-electrical parts of themachinery without switching off the power supply.When activated, the Safe torque off function disables the control voltage of the powersemiconductors of the inverter output stage. This prevents the inverter from generating thetorque required to rotate the motor. If the motor is running when Safe torque off isactivated, it coasts to a stop.
12 Option descriptionExample diagram of STO in R8i modulewith safety relayINVERTER MODULE R8iThe STO function corresponds to Prevention of unexpected start-up as specified byEN 1037:1995 A1:2008 and Uncontrolled stop (stop category 0) as specified inEN 60204-1:2006 AC:2010.Operation principle1. The user opens the Safe torque off circuit with an STO activation switch (or it isopened by a device such as safety relay).2. The STO inputs on the drive/inverter de-energize.3. The STO cuts off the control voltage from the inverter IGBTs.4. The control program generates an indication as defined in the table below.5. Motor coasts to a stop (if running). The drive/inverter cannot restart while theactivation switch or safety relay contacts are open. After the contacts close, a newstart command may be required to start the drive (depends on parameter settings).
Option description 13The table below describes the operation of the STO function in detail depending on: status of the STO inputs the fault or warning START INHIBI (see chapter Maintenance and fault tracing).When drive isHow the STO function operatesSTART INHIBIindicationrunningAwakes and trips the drive.FaultstoppedAwakes and disables start.WarningOne energized, otherde-energizedrunningAwakes and trips the drive.FaultstoppedAwakes and disables start.WarningEnergizedrunning or stoppedSTO is on standby. Drive operatesnormally.-Status of STO inputsDe-energizedSTO status indicationsNote: The indications are not safety classified information.Control programAlarm and status bits / wordsSystem Control Program08.02 AUX STATUS WORD bit 808.21 START INHIBI WORDStandard Control Program03.03 AUX STATUS WORD bit 8Control programAlarms and faultsSystem Control Program09.04 ALARM WORD 1 bit 009.06 FAULT WORD 3 bit 531.02 START INHIBIT ALMStandard Control Program03.08 ALARM WORD 1 bit 0Control programDigital / relay outputsSystem Control Program14 DIGITAL OUTPUTSNote: To be programmed by the user. For information onprogramming the digital outputs, see ACS800 system control programfirmware manual [3AFE64670646 (English)].Standard Control Program14 RELAY OUTPUTSNote: To be programmed by the user. For information onprogramming the relay outputs, see ACS800 standard controlprogram firmware manual [3AFE64527592 (English)].See also chapter Maintenance and fault tracing.
14 Option descriptionSTO function activation and indication response times Module response times onlySTO activation and indication response timesTypical response timeMaximum response timeSTO activation response time 1)2 ms20 msSTO indication response time 2)1.5 ms-1)STO activation response time delay between de-energizing the STO input and switching off the drive/inverter output bridge2)STO indication response time delay between de-energizing the STO input and indication of STO input deenergization Response times with typical safety relaySTO activation and indication response timesTypical response timeMaximum response timeSTO activation response time 3)52 ms70 ms51.5 ms-STO indication response time4)3) STOactivation response time delay between de-energizing the STO relay and switching off the drive/inverter output bridge4) STOindication response time delay between de-energizing the STO relay and indication of STO input deenergization
Installation 153InstallationContents of this chapterThis chapter describes the installation procedure, wiri
ACS800-01/U1 Hardware Manual 3AFE64382101 ACS800-04/04M/U4 Hardware Manual (45 to 560 kW) 3AFE64671006 ACS800-04 Drive Modules Hardware Manual (0.55 to 200 kW) 3AFE68372984 ACS800-11/U11 Hardware Manual 3AFE68367883 ACS800-14 Frequency Converter Modules Supplement 3AFE68458986 ACS800-31/U31 Hardware Manual 3AFE64671006
ABB industrial drives ABB industrial drives ABB industrial drives are highly flexible AC drives, designed for industrial applications, specifically for those in process industries such as the pulp & paper, metals, mining, cement, power, chemical, and oil & gas industries. The drives can be configured to meet the precise needs of
speed feedback when the ACS800 with DTC is used. IndustrialIT enabled ABB industrial drives are IndustrialIT enabled. This guar-antees the user that ABB industrial drives can be easily integrated into ABB Industrial IT systems. Single drives The single drive configuration contains a rectifier, DC link and an inverter in one single AC drive unit.
Catalog ABB industrial drives ACS800 multidrives 3 Contents ABB industrial drives, ACS800, multidrives ABB industrial drives 4 Multidrive main features 8 Technical data 11 Drive and supply units 400, 500 and 690 V 12 ACS800 liquid-cooled multidrives 18 Drive and supply units 400, 500 and 690 V 19 Brake options 25 3-phase high power brake units 26
ABB industrial drives ABB industrial drives are highly fl exible AC drives that can be customized to meet the precise needs of industrial applications. The drives cover a wide power and voltage range up to 5600 kW and 690 V. The drives are designed for industrial applications such as those found in pulp and paper, metals, mining, cement,
8 ABB INDUSTRIAL DRIVES, ACS880, SINGLE DRIVES, CATALOG — Easy to use All-compatible user interface saves commissioning and learning time The ACS880 is part of ABB’s all-compatible drives portfolio. Other drives in this portfolio are the ACS380, ACS480 and ACS580. These drives share the same easy-to-use PC tools and multilingual control panels.
Catalog ABB industrial drives ACS880 single drives 3 The ACS880 series drives are part of ABB’s all-compatible drives portfolio. Compatible with virtually all types of processes, automation systems, users and business requirements they are designed to tackle any motor-driven application, in any industry, whatever the power range. The
Catalog ABB industrial drives ACS880 single drives 3 The ACS880 series drives are part of ABB's all-compatible drives portfolio. Compatible with virtually all types of processes, automation systems, users and business requirements they are designed to tackle any motor-driven application, in any industry, whatever the power range. The
ABB drives for food and beverage industry: — 01 Micro and machinery drives — 02 A, B General purpose drives — 03 Industrial drives — Drives and automation for food and beverage industry — 01 — 02 A — 02 B Drives are an important tool to deliver safety for food and beverage machinery. ABB's Variable Speed Drives (VSD) have been used
