ABB industrial drives

Application guide
ACS800-01/U1/04/04LC/04M/U4/11/U11/14/31/U31/104/104LC
Safe torque off function (+Q967)

List of related manuals

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ACS800-01/U1 Hardware Manual
ACS800-04/04M/U4 Hardware Manual (45 to 560 kW)
ACS800-04 Drive Modules Hardware Manual (0.55 to 200 kW)
ACS800-11/U11 Hardware Manual
ACS800-14 Frequency Converter Modules Supplement
ACS800-31/U31 Hardware Manual

Code (English)
3AFE64382101
3AFE64671006
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3AFE64527592
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Option manuals and general safety guides

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adapters, etc.

3AUA0000048753
1SFC001008B0201
www.abb.com/safety

You can find manuals and other product documents in PDF format on the Internet. See section
Document library on the Internet on the inside of the back cover. For manuals not available in the
Document library, contact your local ABB representative.

Application guide
ACS800-01/U1/04/04LC/04M/U4/11/U11/14/31/U31/104/104LC
Safe torque off function (+Q967)

Table of contents
3. Installation
4. Start-up and use

2015 ABB Oy. All Rights Reserved.

3AUA0000063373 Rev H
EN
EFFECTIVE: 2015-03-12

Table of contents

1. Introduction to the manual

Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Applicability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Target audience . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7
7
7
8
8
9

2. Option description
Contents 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11
11
12
13
14
14
14

3. Installation
Contents 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 . .

15
15
15
15
16
16
16
16
17
17
17
18
18
19
19
20
20
21
22
22
23
24
25
26
27
28

4. Start-up and use

Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Start-up and acceptance test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Competence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Acceptance test reports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Acceptance test procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

29
29
29
30
30
31

5. Maintenance and fault tracing

Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Proof test interval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Competence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fault tracing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Warning messages generated by the drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fault messages generated by the drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

33
33
33
34
34
34
34

6. Technical data
Contents 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 function
implemented 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 . . . . . . . . . . . . . . . . . . . . . . . . . . .
TV certificate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Declarations of Conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

35
35
35
35
35
36
36
37
37
37
37
37
38
39
39
40
41

Further information
Product and service inquiries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Product training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Providing feedback on ABB Drives manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Document library on the Internet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

43
43
43
43

Introduction to the manual 7

1
Introduction to the manual
Contents of this chapter
This chapter describes the manual in short and gives some general information for the
reader.

Applicability
The manual applies to the ACS800-01/04/04LC/04M/11/14/31/104/104LC and
ACS800-U1/U4/U11/U31 drives and inverter modules which have the option +Q967:
Safe torque off (STO).

Safety instructions
Only a qualified electrician who has appropriate knowledge on functional, machine and
process safety is allowed to install, start up and maintain the safety circuit.
WARNING! The Safe torque off function does not disconnect the voltage of the
main and auxiliary circuits from the inverter. Therefore maintenance work on
electrical parts of the inverter or the motor can only be carried out after isolating
the inverter from the main supply.

WARNING! The Safe torque off functionality is only achieved, when the ASTO
board is installed on the inverter module. True Safe torque off functionality is not
achieved, if the option board is installed on other types of modules, such as the
supply unit or the brake unit.

8 Introduction to the manual

WARNING! (With permanent magnet motors only) In case of a multiple IGBT

power semiconductor failure, the inverter system can produce an alignment
torque which maximally rotates the motor shaft by 180/p degrees regardless of
the 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 only
includes the instructions related to the scope of this manual.

Target audience
This manual is intended for people who install, start up, use and service the drive safety
option. Read the manual before working on the drive. You are expected to know the
fundamentals of electricity, wiring, electrical components, electrical schematic symbols,
and functional safety.

Contents
The chapters of this manual are briefly described below.
Introduction to the manual (this chapter) introduces this manual and gives safety
instructions.
Option description describes the Safe torque off (STO) function of the drive and inverter
modules 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 Safe
torque off function.
Start-up and use contains the start-up and acceptance test procedure for the Safe torque
off function and gives instructions for its use.
Maintenance and fault tracing describes the maintenance procedure, required
competence for maintenance personnel and fault tracing information for the Safe torque
off function.
Technical data contains the technical details of the ASTO-11 and ASTO-21 boards, the
safety data for the STO and example information of safety relays, safety logic and
activation switches. It also lists the related standards and directives, and contains the TV
certificate and declarations of conformity with the European Machinery Directive.

Introduction to the manual 9

Abbreviations
Abbreviations used in this manual are listed below.
Abbr.

Reference

ASTO
Cat.

Description
Safe torque off board

EN ISO 13849-1

Category. Classification of the safety-related parts of a control system in

respect of their resistance to faults and their subsequent behavior in the
fault condition, and which is achieved by the structural arrangement of
the parts, fault detection and/or by their reliability. The categories are: B,
1, 2, 3 and 4.

CCF

EN ISO 13849-1

Common cause failure (%)

DC

EN ISO 13849-1

Diagnostic coverage

HFT

IEC 61508

Hardware fault tolerance

MTTFd

EN ISO 13849-1

Mean time to dangerous failure: (The total number of life units) / (the
number of dangerous, undetected failures) during a particular
measurement interval under stated conditions.

PFD

IEC 61508

Probability of failure on demand

PFH

IEC 61508

Probability of dangerous failures per hour

PL

EN ISO 13849-1

Performance level. Levels ae correspond to SIL.

SC

IEC 61508

Systematic capability

SFF

IEC 61508

Safe failure fraction (%)

SIL

IEC 61508

Safety integrity level (13)

SILCL

IEC/EN 62061

Maximum SIL (level 13) that can be claimed for a safety function or
subsystem

SS1

IEC/EN 61800-5-2

Safe stop 1

STO

IEC/EN 61800-5-2

Safe torque off

T1

IEC 61508

Proof test interval. T1 is a parameter used to define the probabilistic

failure rate (PFH or PFD) for the safety function or subsystem.
Performing a proof test at a maximum interval of T1 is required to keep
the SIL capability valid. The same interval must be followed to keep the
PL capability (EN ISO 13849) valid. Note that any T1 values stated
cannot be regarded as a guarantee or warranty. See also section Proof
test interval on page 33.

10 Introduction to the manual

Option description 11

2
Option description
Contents of this chapter
This chapter describes the Safe torque off (STO) function of the drive and inverter
modules and lists the indications and response times of the Safe torque off function.

Description
The Safe torque off function can be used, for example, to construct safety or supervision
circuits 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 enables
short-time maintenance operations like cleaning or work on non-electrical parts of the
machinery without switching off the power supply.
When activated, the Safe torque off function disables the control voltage of the power
semiconductors of the inverter output stage. This prevents the inverter from generating the
torque required to rotate the motor. If the motor is running when Safe torque off is
activated, it coasts to a stop.

12 Option description

Example diagram of STO in R8i module

with safety relay

INVERTER MODULE R8i

The STO function corresponds to Prevention of unexpected start-up as specified by

EN 1037:1995 + A1:2008 and Uncontrolled stop (stop category 0) as specified in
EN 60204-1:2006 + AC:2010.

Operation principle
1. The user opens the Safe torque off circuit with an STO activation switch (or it is
opened 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 the
activation switch or safety relay contacts are open. After the contacts close, a new
start command may be required to start the drive (depends on parameter settings).

Option description 13

The 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 is

How the STO function operates

START INHIBI
indication

running

Awakes and trips the drive.

Fault

stopped

Awakes and disables start.

Warning

One energized, other

de-energized

running

Awakes and trips the drive.

Fault

stopped

Awakes and disables start.

Warning

Energized

running or stopped

STO is on standby. Drive operates

normally.

Status of STO inputs

De-energized

STO status indications

Note: The indications are not safety classified information.
Control program

Alarm and status bits / words

System Control Program

08.02 AUX STATUS WORD bit 8

08.21 START INHIBI WORD

Standard Control Program

03.03 AUX STATUS WORD bit 8

Control program

Alarms and faults

System Control Program

09.04 ALARM WORD 1 bit 0

09.06 FAULT WORD 3 bit 5
31.02 START INHIBIT ALM

Standard Control Program

03.08 ALARM WORD 1 bit 0

Control program

Digital / relay outputs

System Control Program

14 DIGITAL OUTPUTS
Note: To be programmed by the user. For information on
programming the digital outputs, see ACS800 system control program
firmware manual [3AFE64670646 (English)].

Standard Control Program

14 RELAY OUTPUTS
Note: To be programmed by the user. For information on
programming the relay outputs, see ACS800 standard control
program firmware manual [3AFE64527592 (English)].

See also chapter Maintenance and fault tracing.

14 Option description

STO function activation and indication response times

Module response times only
STO activation and indication response times

Typical response time

Maximum response time

STO activation response time 1)

2 ms

20 ms

STO 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 bridge

2)

STO indication response time = delay between de-energizing the STO input and indication of STO input deenergization

Response times with typical safety relay

STO activation and indication response times

Typical response time

Maximum response time

STO activation response time 3)

52 ms

70 ms

51.5 ms

STO indication response time

4)

3) STO

activation response time = delay between de-energizing the STO relay and switching off the drive/
inverter output bridge

4) STO

indication response time = delay between de-energizing the STO relay and indication of STO input deenergization

Installation 15

3
Installation
Contents of this chapter
This chapter describes the installation procedure, wiring and allowed cable type of the
Safe torque off function.

Supply voltage
WARNING! The supply voltage of the STO circuit (ASTO boards) is 24 V DC.
Never supply the ASTO board with 230 V AC or 115 V AC. This can damage the
board and it must be replaced.
Note: Since former option +Q950 (Prevention of unexpected start-up function) uses 230 V
or 115 V supply voltage, it is not possible to use it with Safe torque off function (option
+Q967) or vice versa. Note this when using spare parts.
Note: The Safe torque off function can be installed afterwards (that is, after the factory
assembly) to drive modules. Contact ABB Drives Service for further information.

Connections
STO input
The STO input can be supplied from an external power supply or from an RMIO control
unit 24 V DC output. In both cases the requirements given below must be fulfilled.

16 Installation

Specifications of the STO input:

Connector pitch: 5.08 mm, maximum wire size 2.5 mm2

Operation voltage: 24 V DC +/- 10%

Logic levels: "0" < 5 V DC, "1" > 17 V DC
For the drive to start, both STO inputs must be "1".
Current consumption: 20 mA per STO channel.

Note: If an external power supply is used for the STO, the power supply must have overvoltage and over-current protections.
Note: For STO input connection diagrams and pin numbers, see the following connection
diagrams.

Activation switch
The activation switch is shown in the diagram on page 22 as well as in the Safe torque off
with safety relay examples. This represents a component such as a manually operated
switch, an emergency stop push button, the contacts of a safety relay or a safety PLC.
If a manually operated activation switch is used, the switch must be of a type that can be
locked out to the open position.

Cable types and lengths

Cable between STO activation switch and drive/inverter module or ASTO board
The cable from the STO activation switch runs to the drive/inverter module connector in
frame sizes R2i-R8i and R7-R8. In frame sizes R2-R6, the cable runs from the STO
activation switch to an external ASTO board. This cable is not included in the delivery but it
must be acquired by the customer. Make sure that it meets the specifications in this
section.
A single-shielded twisted-pair cable is required.
Maximum cable lengths:
300 m (980 ft) between the activation switch and ASTO board.
Cable between ASTO board and drive/inverter module
Only the WSTO wire harnesses supplied with the Safe torque off option board can be used
between the ASTO and the INT board within the drive/inverter module. The SIL/PL
classification is only valid when the WSTO wire harnesses are used.
Drive modules, frame sizes R2...R6 with an external ASTO board
Use only the cable ordered for the ASTO board and included in the delivery (type WSTO).
Several cable lengths are available. The options are shown in the table below.
Name

Length (mm)

Code

WSTO-02

185

3AUA0000067819

WSTO-03

305

3AUA0000067820

WSTO-04

3000

3AUA0000067823

WSTO-05

10000

3AUA0000050722

WARNING! Drive modules, frame sizes R2...R6: For connecting the ASTO board
and the module, use only the wire kits delivered by ABB. If you use other cables or
modify the cables, you may cause a malfunction of the drive.

Installation 17

Example wiring diagrams

Connect the cables as shown in the diagram below. For more information on the
components, see chapter Technical data.

STO connections without safety relays

The following diagrams show the STO connections without safety relays in:
connecting an emergency stop push button to the drive/inverter module without safety
relay (page 22).

single drives R2-R6 and R7-R8 (page 18)

inverter modules R2i-R4i, R5i, R7i, R8i, R7iLC and R8iLC (pages 19-21)

Connecting the STO activation switch

We recommend using a safety relay between the activation switch and the STO input,
because the STO is not capable of detecting any redundancy fault of the switch (such as a
welded contact).

INVERTER MODULE R8i

3AUA0000096631

18 Installation

Frame sizes R2 to R6

RINT-XXXX / GINT-XXXX

3AUA0000072542

Frame sizes R7 and R8

3AUA0000072272

Installation 19

Frame sizes R2i to R4i

3AUA0000077408

Frame size R5i

3AUA0000077456

20 Installation

Frame size R7i

3AUA0000077458

Frame size R8i

3AUA0000077457

Installation 21

Liquid-cooled modules of frame sizes R7i and R8i

3AUA0000077142

22 Installation

STO connections with safety relays

The following diagrams show examples of STO connections with safety relays for:
single drives R2-R6 and R7-R8 (page 22)

inverter modules R2i-R4i, R5i, R7i and R8i (pages 24-27)

multiple drive/inverter modules or inverter units (page 28).

Note: The safety relay is not included in the delivery when the drive is equipped with
option +Q967. In the examples below, the recommended customer wiring of the safety
circuit (the activation switch, safety relay and ASTO board) are shown with a dashed line
(on the customers responsibility). The connection from ASTO board to drive/inverter is
shown with a solid line (included in STO kit deliveries).
Frame sizes R2 to R6

RINT-XXXX / GINT-XXXX

3AUA0000072271

Installation 23

Frame sizes R7 and R8

3AUA0000078208

24 Installation

Frame sizes R2i to R4i

INVERTER MODULE R2i, R3i AND R4i

3AUA0000071122

Installation 25

Frame size R5i

INVERTER MODULE R5i

3AUA0000071141

26 Installation

Frame size R7i

INVERTER MODULE R7i

3AUA0000071142

Installation 27

Frame size R8i

INVERTER MODULE R8i

3AUA0000071143

28 Installation

Connecting several drive/inverter modules or inverter units to one safety relay

In the example, R8i modules are used, but the same principle applies to any frame size.

INVERTER MODULE R8i

INVERTER MODULE R8i

3AUA0000096632

Start-up and use 29

4
Start-up and use
Contents of this chapter
This chapter contains the start-up and acceptance test procedure for the Safe torque off
function and gives instructions for its use.

Start-up and acceptance test

To ensure the safe operation of a safety function, validation is required. The final
assembler of the machine must validate the function by performing an acceptance test.
The acceptance test must be performed
at initial start-up of the safety function

after any changes related to the safety function (circuit boards, wiring, components,
settings, etc.)

after any maintenance work related to the safety function.

Competence
The acceptance test of the safety function must be carried out by a competent person with
adequate expertise and knowledge of the safety function as well as functional safety, as
required by IEC 61508-1 clause 6. The test procedures and report must be documented
and signed by this person.

30 Start-up and use

Acceptance test reports

You must store the signed acceptance test reports in the logbook of the machine. The
report must include, as required by the referred standards:
description of the safety application (including a figure)

a description and revisions of safety components that are used in the safety
application (STO and other components)

a list of all safety functions using STO that are used in the safety application

documentation of start-up activities, references to failure reports and resolution of

failures

the test results for each safety function, checksums (not relevant for the STO safety
component), date of the tests and confirmation by the test personnel.

a list of all safety related parameters and their values (STO has no safety-related
parameters)

You must store any new acceptance tests performed due to changes or maintenance in
the logbook of the machine.

Acceptance test procedure

After wiring the Safe torque off function, validate its operation as follows.
Action
WARNING! Obey the safety instructions given in the relevant hardware manual and ACS800
Multidrive and Multidrive modules Safety Instructions (3AFE64760432 [English]). If you
ignore them, it can cause physical injury or death, or damage to the equipment.
Ensure that the drive/inverter can be run and stopped freely during start-up.
Stop the drive/inverter (if running), switch the input power off and isolate the drive/inverter from the
power line by a disconnector.
Check the Safe torque off circuit connections against the wiring diagram.
Close the disconnector and switch the power on.
Test the operation of the STO function when the motor is stopped.
Give a stop command for the drive/inverter (if running) and wait until the motor shaft is at a
standstill.
Ensure that the drive/inverter operates as follows:
Open the STO circuit. The drive/inverter generates a "START INHIBI" warning.
Give a start command to verify that the STO function blocks the operation of the drive/inverter. The
motor should not start.
Close the STO circuit.
Reset any active faults. Restart the drive/inverter and check that the motor runs normally.
Test the operation of the STO function when the motor is running.
Start the drive/inverter and ensure the motor is running.
Open the STO circuit. The motor should stop. The drive/inverter generates a "START INHIBI" fault.
Reset any active faults and try to start the drive/inverter.
Ensure that the motor stays at a standstill and the drive/inverter operates as described above in
testing the operation when the motor is stopped.
Close the STO circuit.
Reset any active faults. Restart the drive/inverter and check that the motor runs normally.
Document and sign the acceptance test report which verifies that the safety function is safe and
accepted for operation.

Start-up and use 31

Note: The drive/inverter indications are described in more detail in section STO status
indications on page 13.

Use
1. Open the activation switch, or activate the safety functionality that is wired to the STO
connection.
2. STO inputs on the ASTO board de-energize, and the ASTO board cuts off the control
voltage from the drive/inverter IGBTs.
3. The control program generates an indication as defined in section STO status
indications on page 13.
4. The motor coasts to a stop (if running). The drive/inverter cannot restart while the
activation switch or safety relay contacts are open. After the contacts close, a new
start command may be required to start the drive (depends on parameter settings).
5. Deactivate the STO by closing the activation switch, or resetting the safety
functionality that is wired to the STO connection.
6. Reset any faults before restarting.

WARNING! The Safe torque off functionality is only achieved, when the ASTO
board is installed on the inverter module. True Safe torque off functionality is not
achieved, if the option board is installed on other types of modules, such as the
supply unit or the brake unit.

WARNING! (With permanent magnet motors only) In case of a multiple IGBT

power semiconductor failure, the inverter system can produce an alignment
torque which maximally rotates the motor shaft by 180/p degrees regardless of
the activation of the Safe torque off function. p denotes the number of pole pairs.
Notes:
If a running drive/inverter is stopped by using the Safe torque off function, the drive/
inverter will cut off the motor supply voltage and the motor will coast to a stop. If this
causes danger or is not otherwise acceptable, stop the drive/inverter and machinery
using the appropriate stop mode before activating the Safe torque off function.

The Safe torque off function overrides all other functions of the drive/inverter.
The Safe torque off function is ineffective against deliberate sabotage or misuse.
The Safe torque off function has been designed to reduce the recognized hazardous
conditions. In spite of this, it is not always possible to eliminate all potential hazards.
The assembler of the machine must inform the final user about the residual risks.

32 Start-up and use

Maintenance and fault tracing 33

5
Maintenance and fault tracing
Contents of this chapter
This chapter describes the maintenance procedure, required competence for maintenance
personnel and fault tracing information for the Safe torque off function.

Maintenance
In addition to proof testing, it is a good practice to check the operation of the function when
other maintenance procedures are carried out on the machinery.
Include the Safe torque off operation test described above in the routine maintenance
program of the machinery that the drive/inverter runs.
If any wiring or component change is needed after start up, follow the test given in section
Acceptance test procedure (page 30).
Use only ABB approved spare parts.
Record all maintenance and proof test activities in the machine logbook.

Proof test interval

After the operation of the circuit is validated at start-up, the STO function shall be
maintained by periodic proof testing. In high demand mode of operation, the maximum
proof test interval is 20 years. In low demand mode of operation, the maximum proof test
interval is 2 years (high or low demand as defined in IEC 61508, EN/IEC 62061 and
EN ISO 3849-1). The test procedure is given in section Acceptance test procedure
(page 30).

34 Maintenance and fault tracing

The person responsible for the design of the complete safety function should also note the
Recommendation of Use CNB/M/11.050 published by the European co-ordination of
Notified Bodies concerning dual-channel safety-related systems with electromechanical
outputs:
When the safety integrity requirement for the safety function is SIL 3 or PL e (cat. 3 or
4), the proof test for the function must be performed at least every month.

When the safety integrity requirement for the safety function is SIL 2 (HFT = 1) or PL d
(cat. 3), the proof test for the function must be performed at least every 12 months.

This is a recommendation and depends on the required (not achieved) SIL/PL. For
example, safety relays, contactor relays, emergency stop buttons, switches etc. are
typically safety devices which contain electromechanical outputs. The STO circuit of the
inverter unit does not contain any electromechanical components.

Competence
The maintenance and proof test activities of the safety function must be carried out by a
competent person with adequate expertise and knowledge of the safety function as well as
functional safety, as required by IEC 61508-1 clause 6.

Fault tracing
Warning messages generated by the drive
Warning

Cause

What to do

START INHIBI

Safe torque off function has been

activated while the drive was stopped.

Close Safe torque off function switch. If the

switch is closed and the warning is still
active, check power supply at ASTO board
input terminals. Replace ASTO board.

Fault messages generated by the drive

Fault

Cause

What to do

GD
DISABLED X

ASTO board power supply of parallelconnected R8i inverter module has been
switched off during run. X (112) refers
to inverter module number.

Check Safe torque off function circuit of this

module (X).

Safe torque off has been activated during

motor run or motor start command has
been given when Safe torque off is
active.

Close Safe torque off function switch. If the

switch is closed and the fault is still active,
check power supply at ASTO board input
terminals. Replace ASTO board.

START INHIBI

Replace ASTO board of R8i inverter

module.

Any failures of the Safe torque off function must be reported to ABB.

Technical data 35

6
Technical data
Contents of this chapter
This chapter contains the technical details of the ASTO-11 and ASTO-21 boards, the
safety data for the STO components and example information of safety relays and
activation switches. It also lists the related standards and directives, and contains the TV
certificate and declarations of conformity with the European Machinery Directive.

STO components
ASTO-11/21 board
ASTO-11 and ASTO-21 board
Supply voltage range

+24 V DC +/- 10%

Current consumption

40 mA (20 mA/channel)

Supply cable

A single-shielded twisted pair

Maximum cable length

300 m

Conductor min. cross section

0.5 mm2, 20 AWG

Logic levels

"0" < 5 V DC, "1" > 17 V DC

Ambient temperature

050 C

Relative humidity

Max. 90%, no condensation allowed

Altitude in operation

02000 m

ASTO-11 board
Dimensions

167 x 128 x 52 mm (height x weight x depth)

Weight

0.75 kg

Degree of protection

IP20

36 Technical data

Note: Supply from semiconductor safety output with test pulse may lead to unnecessary
trips. Contact ABB for further information.
ASTO board according to frame size of the module
Frame size

ASTO-11/21 board

R2iR5i

ASTO-11

R2R6

ASTO-11

R7iR8i

ASTO-21

R7R8

ASTO-21

Note: In frame sizes R2R6 of the ACS800-01, -U1, -04, -04M, -04LC, -U4, -11, -U11, -31
and -U31 drives the ASTO board is ASTO-11 with enclosure. In frames R7R8 and
R2iR8i the ASTO board is inside the drive module.
Dimensions of the ASTO board with enclosure

3AUA0000068698

Technical data 37

STO safety relay type

General requirements

IEC 61508 and/or EN/ISO 13849-1

Example 1

Simple SIL3 approved safety relay

Type and manufacturer

DOLD LG 5925.48/60 AC/DC 24 V

ABB BT50 24DC

Approvals

SILCL 3 according to EN 62061 and PL e according to EN ISO 13849-1

Example 2

Programmable safety logic

Type and manufacturer

ABB AC500-S

Approvals

IEC 61508, SIL3; and EN ISO 13849-1, PL e

Push-button to be used with emergency stop

Type

A push-button operated switch with a palm or mushroom head type.

Actuators of emergency stop devices are colored red.

Example

ABB CE4T-10R-02

Switch to be used with Prevention of unexpected start-up function

implemented with STO

Type

A lockable selector switch with a reliable and unambiguous indication of

positions.

Example

Kraus & Naimer

DH11 A291-600, FT22-V+S0V845/A11/D11

Safety data
Note: The safety relay is not included in the safety data given in this chapter.

STO in ACS800 drives and inverter modules

The data applies to both air-cooled and liquid-cooled modules.
SFF

PFH

PFD

(1/h)

T1= 2 a

SIL/
SILCL

SC

R2, R2i

>90

3,63E-10

R3, R3i

>90

3.63E-10

Frame size

PL

(%)

MTTFd

DC

Lifetime
Cat.

HFT

CCF

(a)

(%)

3.54E-06

5373

>90

65

20

3.54E-06

5373

>90

65

20

T1 =20 a

(a)

R4, R4i

>90

8.11E-10

7.50E-06

4987

>90

65

20

R5, R5i

>90

5.67E-10

5.34E-06

5190

>90

65

20

65

20

65

20

R6

>90

3.97E-10

3.85E-06

5341

>90

R7, R7i,
R8, R8i

>90

8.72E-10

8.03E-06

4993

>90

3AXD10000342876 Rev A

38 Technical data

Multiples of frame size R8i

Above values for frame sizes R7/R7i/R8/R8i apply for the multiples of frame size R8i,
except for values of PFH, PFD and MTTFd. These values are listed below.
Frame size

PFH

PFD

(1/h)

T1= 2 a

T1 =20 a

MTTFd
(a)

2R8i

1.74E-09

1.61E-05

2497

3R8i

2.62E-09

2.41E-05

1664

4R8i

3.49E-09

3.21E-05

1248

5R8i

4.36E-09

4.01E-05

999

6R8i

5.23E-09

4.82E-05

832

7R8i

6.10E-09

5.62E-05

713

8R8i

6.97E-09

6.42E-05

624

9R8i

7.85E-09

7.23E-05

555

10R8i

8.72E-09

8.03E-05

499

11R8i

9.59E-09

8.83E-05

454

12R8i

1.05E-08

9.63E-05

416

3AXD10000342876 Rev A

The following temperature profile is used in safety value calculations:

670 on/off cycles per year with T = 71.66 C

1340 on/off cycles per year with T = 61.66 C
30 on/off cycles per year with T = 10.0 C
32 C board temperature at 2.0% of time
60 C board temperature at 1.5% of time
85 C board temperature at 2.3% of time.

The STO is a type A safety component as defined in IEC 61508-2.

Relevant failure modes:
The STO trips spuriously (safe failure)
The STO does not activate when requested
A fault exclusion on the failure mode short circuit on printed circuit board has been
made (EN 13849-2, table D.5). The analysis is based on an assumption that one
failure occurs at one time. No accumulated failures have been analyzed.
Reaction times are described in section STO function activation and indication
response times on page 14.

Technical data 39

Related standards and directives

The Safe torque off function of the inverter complies with these standards:
Standard

Name

EN 60204-1:2006 + AC:2010
IEC 60204-1:2005 + A1:2008

Safety of machinery Electrical equipment of machines Part 1: General

requirements

IEC 61508-1:2010

Functional safety of electrical/electronic/programmable electronic safetyrelated systems Part 1: General requirements

IEC 61508-2:2010

Functional safety of electrical/electronic/programmable electronic safetyrelated systems Part 2: Requirements for electrical/electronic/
programmable electronic safety-related systems

IEC 61511:2003

Functional safety Safety instrumented systems for the process industry

sector

IEC/EN 61800-5-2:2007

Adjustable speed electrical power drive systems

Part 5-2: Safety requirements Functional

IEC/EN 62061:2005 +
AC:2010 +A1:2013

Safety of machinery Functional safety of safety-related electrical,

electronic and programmable electronic control systems

EN ISO 13849-1:2008 +
AC:2009

Safety of machinery Safety-related parts of control systems Part 1:

General principles for design

EN ISO 13849-2:2012

Safety of machinery Safety-related parts of control systems Part 2:

Validation

2006/42/EC

European Machinery Directive

The Safe torque off function also corresponds to Prevention of unexpected start-up as
specified by EN 1037:1995 + A1:2008 and Uncontrolled stop (stop category 0) as
specified in EN 60204-1:2006 + AC:2010.

Compliance with the European Machinery Directive

The drive is an electronic product which is covered by the European Low Voltage
Directive. However, the drive internal safety function of this manual (option +Q967) is in
the scope of the Machinery Directive as a safety component. This function complies with
European harmonized standards such as EN/IEC 61800-5-2. The declarations of
conformity are given below.

40 Technical data

TV certificate

Technical data 41

Declarations of Conformity

42 Technical data

Further information
Product and service inquiries
Address any inquiries about the product to your local ABB representative, quoting the type
designation and serial number of the unit in question. A listing of ABB sales, support and
service contacts can be found by navigating to www.abb.com/searchchannels.

Product training
For information on ABB product training, navigate to www.abb.com/drives and select
Training courses.

Providing feedback on ABB Drives manuals

Your comments on our manuals are welcome. Go to www.abb.com/drives and select
Document Library Manuals feedback form (LV AC drives).

Document library on the Internet

You can find manuals and other product documents in PDF format on the Internet. Go to
www.abb.com/drives and select Document Library. You can browse the library or enter
selection criteria, for example a document code, in the search field.

Contact us

www.abb.com/drives
www.abb.com/drivespartners

3AUA0000063373 Rev H (EN) 2015-03-12