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9CSC006267e-PROFIsafe Safety Functions Module

FSPS-21 E-learning
© 2023 ABB. All rights reserved.

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Drive-based functional safety
Suitable for a wide range of industries and applications

Pulp & paper Extruders Centrifuges & decanters Conveyors

Woodworking mach. Cranes Food processing Metal lines

Food & beverage Automatic storage Amusement parks Pumps & fans

And for all other applications where safety is needed

There’s a wide range of applications where ABB’s drive-based functional safety solutions
can be used. From simple pump and fan applications to complex, multi-axle paper mill
applications. Almost all applications nowadays require safety features, and with ABB’s
drive-based functional safety solutions, we have the right solution for the customer.

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Smart, integrated, drive-based functional safety solutions
Scalable options for optimal control of industry applications
PROFIsafe Safety functions module
FSPS-21
Option 1 - Safe stopping over PROFIsafe
- STO, SS1-t
Drive Motor Applications in many industries
PLC

Safety functions module

FSO-12
Option 2 - Safety functions with safe
speed estimation
- STO, SS1, SSE, SLS, SMS, POUS
- Safety I/O’s
Safety functions module
FSO-21
- Safety functions with
Option 3 safety encoder
- STO, SS1, SSE, SLS, SMS,
POUS, SDI, SSM
- Safety I/Os

ABB Drives’ scalable functional safety offering for optimal safety and control of industry
applications.
With option 1, FSPS-21, the drive can be controlled via PROFINET and safely stopped via
PROFIsafe. FSPS-21 has integrated functionality of FENA-21 and safety functions.
This option is mainly for applications where safe stopping functions are enough and the
drive is controlled with a PLC.
Option 2, FSO-12, is for applications where safety functions based on safe speed
estimation and safety I/Os are needed.
Option 3, FSO-21, is for applications where a safety encoder is need for precise control.
This is for applications where a safety encoder is essential e.g. controlling a crane hoist.
Both FSOs can be used with PROFIsafe and PROFINET when FPNO-21 is used together
with them.

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Drive-based functional safety
Products and tools
Safety option modules PROFIsafe safety functions ATEX-certified thermistor Tools
module protection modules

Drive
composer pro
with graphical
user interface
CPTC-01 FPTC-01 for safety
FSPS-21
FSE-31
FSO-12

FSO-21
FPTC-02
Functional
safety design
tool, FSDT-01

For ACS380 machinery drives,

For ACS880 ACS580 general-purpose For ACS580 general-purpose
industrial drives drives, drives,
ACS880 industrial drives ACS880 industrial drives
*Prices are based on single component orders

The drive-based functional safety (DBFS) products and tools portfolio includes the
Functional Safety Option modules, FSO-12 & -21, FSE-31 and our latest development, FSPS-
21. We also have safe motor temperature modules FPTC-01, -02 and CPTC-02. To
commission and configure these safety option modules, there is a safety graphical user
interface (Safety GUI). To help in the FS design and verification of the safety functions,
there’s our FSDT-01 tool.
Drive-based functional safety supports PROFIsafe over the PROFINET protocol.

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Drive-based functional safety offering
Module Supporte Safety functions PROFIsafe Other Safety level
d drives
FSPS-21 ACS380 STO Integrated No safety I/Os SIL 3 / PL e
ACS580 SS1-t
ACS880
FSO-12 ACS880 STO SMS Requires FENA-21 or FPNO-21 Safety I/Os SIL 3 / PL e
SS1-t & SS1-r SBC 8 inputs
SSE POUS 6 outputs
SLS **PROFIsafe required for this feature
varSLS**
FSO-21 ACS880 STO SMS Requires FENA-21 or FPNO-21 Safety I/Os SIL 3 / PL e
SS1-t & SS1-r SBC 8 inputs
SSE POUS **PROFIsafe required for this feature 6 outputs
SLS SSM *Requires FSE-31 and safety encoder
varSLS** SDI*

FSE-31 ACS880 Incremental HTL Can be used together with FSO-21 + FENA-21 Supports only one incremental HTL SIL 3 / PL e
(can be used only safety encoder Can provide safe speed & position encoder
with FSO-21) interface for FSO-21 information to PLC through PROFIsafe
FPCT-01 ACS880 SMT N/A Not ATEX-certified SIL 2 / PL c

Can be used together with FSO

FPTC-02 ACS880 SMT N/A ATEX-certified SIL 2 / PL c

Can be used together with FSO

CPTC-02 ACS580 SMT N/A ATEX-certified SIL 2 / PL c

Here’s an overview of the drive-based functional safety offering in more detail.

The FSPS-21 module is supported by the all-compatible drives ACS380, ACS580 & ACS880.
FSPS-21 has only two safe stopping functions: Safe Torque Off (STO), and Safe Stop 1,
time-controlled (SS1-t). These functions can be only triggered through a safety PLC.
This means that the FSPS-21 can only be used in systems where there is a safety PLC (or a
PLC with integrated safety features).
FSPS-21 doesn’t have any safety I/Os in it, so all control commands come from the PLC.
FSPS-21 can achieve the highest SIL & PL levels in machinery safety: SIL 3 & PL e.

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PROFIsafe safety functions module, FSPS-21
Market drivers and trends
The Internet of Things (IoT) or Industry 4.0 megatrend is connecting automation systems to the network
• Machine control systems are connected in plants via Fieldbus

Safety functions are being integrated into motion control

• EN 61800-5-2 safety function standard for power drive systems
• Emergency stopping, prevention of unexpected start-up, safe speed monitoring functions
• Machinery application standards (EN ISO 13849-1, EN 62061)

Integrated safety is modular, versatile and intelligent

• Connect and configure, multiple functions in one system

Solutions rather than components

• Certified safety blocks, safety data and example solutions
• Products in solution format is a strong concept in the market

Market drivers and trends to support this new FSPS-21 PROFIsafe safety functions module
are the increasing digitalization, integrated safety functionality and solution-based
offering.
As digitalization transforms the industry, more and more devices are being connected to
the same systems to work seamlesly together. With FSPS-21, it is possible to connect a
drive to a PROFINET network so that the drive can be controlled through it and can be
safely stopped through PROFIsafe.

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Why and when should FSPS be selected?

If not, no safety option is needed.

Is safety needed for the application?

Is safe stopping (STO or SS1-t) enough

If not, offer FSO instead of
for the application?
FSPS-21.

Does the application have a safety PLC If not, offer FSO instead of FSPS-
that supports PROFIsafe over PROFINET 21.
(e.g. ABB, Siemens, Phoenix contact)?

Can the safety solution be realized If safety I/Os are needed, offer FSO instead of
without safety I/Os in the drive? FSPS-21.

Offer FSPS-21 together The customer should answer all these

with all-compatible drives questions based on their safety needs,
which are based on their risk assessment.

Why and when should FSPS-21 be selected?

Well the first question is of course whether safety functionality is needed in the
application.
Secondly, is safe stopping functionality enough for the application, either STO or SS1-t?
Thirdly, does the application have a safety PLC?
And fourthly, can safety be realiazed without safety I/Os?
If the customer answers yes to all of these questions, then FSPS-21 is the appropriate
safety option module for their purposes.

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Value proposition
FSPS-21

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Safe stopping over PROFIsafe, FSPS-21
Value proposition
Maximized safety and conformity
- Fulfilling the highest performance requirements in machinery safety – up to SIL3 / Maximized safety
PLe
- Quality and conformity with TÜV-certified components, tools and functional safety
management system Seamless
integration
Seamless integration
- Simplified control and coordination of multiple drives through PROFIsafe over
PROFINET
- One wire to control drive and safety functionality

Simplicity Simplicity
- One solution for all all-compatible drives
- Same configuration interface and tools for all the products
- Only Fieldbus configuration needed (plug and play)
Compact and
cost-effective
Compact and cost effective solutions
solutions
- Functional safety and Fieldbus integrated into one package
- Integrated solution - reduced component cost, engineering and space
- No wearing parts, no need for maintenance or regular testing

With the FSPS-21 PROFIsafe safety functions module, customers can maximize safety in
their application with the highest reliability levels (SIL 3 / PL e). With FSPS-21, it’s possible
to safely stop a motor through PROFIsafe by using Safe Torque Off (STO) or Safe Stop 1
(SS1-t) for controlled safe stopping.
The quality and conformity of this solution is certified and verified by TÜV-Nord. Also, ABB
Drives have a functional safety management system to gurantee that all necessary
requirements are fulfilled during the whole life cycle of the safety products.

As this module is meant for seamless integration between the PLC and the drive(s), it
simplifies the control and coordination of multiple drives through PROFIsafe over
PROFINET.
It allows customers to use only one wire from the PLC to the drives, which can be used for
the PC-tool network, drive control and safety communication in a seamless way.

This simplified solution is for all-compatible drives (ACS380, ACS580 & ACS880). Even the
configuration of the module is made easy, as it only requires Fieldbus parameters to be
set in the drive.
The configuration of this module can be done either via control panel or with the Drive
composer PC-tool.

With this solution, it is possible to reduce the overall costs of the system design, as only
one integrated module is needed for safety and connectivity, and it only requires one
Ethernet cable from the PLC to the drive to control it and for safety.

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PROFIsafe safety functions module, FSPS-21
Simplicity
Learn it once, use it
everywhere Easy commissioning Integrated solution Safety connectivity

FSPS-21

One solution for Only Fieldbus settings Only one module for PROFIsafe over PROFINET
several all-compatible need to be set up connectivity & safety connectivity
drives

One solution for several all-compatible drives

Common functionality, user interface and tools

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Technical data
FSPS-21

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Drive-based Functional Safety
PROFIsafe safety Functions module, FSPS-21
Product overview
– Provide PROFIsafe over PROFINET connection between
the Safety PLC and the drive
– Works only with safety PLC
– Safely stop the drive via PROFIsafe
• STO & SS1-t safe stopping functions
– TÜV-certified, PL e & cat.3 / SIL 3
– Supported drives: ACS380, ACS580 & ACS880
– Get the STO status of the drive via the PROFINET
connection
– Control the drive through PROFINET same way as a
standard PROFINET I/O module
– PROFINET cycle time: 4 ms
– Other PROFINET features:
• Shared device
• Media Redundancy Protocol (MRP)
• Tool network (one wire)
D
e
c
e
S
m
lb
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r
d

With the FSPS-21 PROFIsafe safety functions module, it’s possible to control the drive via
PROFINET and safely stop the drive via PROFIsafe.
As the module establishes the PROFIsafe communication between the drive and safety
PLC, it is necessary to have the PROFIsafe communication up and running before the
FSPS-21 allows the STO function to be reset.
FSPS-21 have two SIL 3 / PL e rated safety functions available: Safe Torque Off (STO), and
Safe Stop 1, time-controlled (SS1-t).
FSPS-21 can be used together with ACS880 industrial drives, ACS580 general-purpose
drives and ACS380 machinery drives.
Basically, FSPS-21 has all the same PROFINET features as FPNO-21, except the PROFInet
cycle time is 4 milliseconds with FSPS-21, whereas with FPNO-21 it is 1 millisecond.

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Safety functions of FSPS-21 module
Supports two safety functions
Safety function active
Function request, demand

no motor torque
|n|
STO – Safe Torque Off
Speed
(Category 0 Stop – EN 60204-1) 0 Coast stop
time t

time delay
|n|
SS1-t – Safe Stop 1,
time controlled Speed
(Category 1 Stop – EN 60204-1) Ramp stop
0
t
Safe torque off (STO)
- no motor torque

This is a brief description of the safety functions supported by the FSPS-21 PROFIsafe
safety functions module.
To illustrate how the safety functions operate, we examine what happens when a stop
request is activated. The red line in the diagram indicates when a stop is requested.
– The Safe Torque Off function cuts off a drive’s output to the motor, and causes the
machine to coast to a stop.
– The Safe Stop 1 function activates a controlled stop function, followed by Safe
Torque Off. The ramp stop function is monitored by time.

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PROFIsafe safety functions module, FSPS-21
Module details

Mechanical locking pin

MAC ID

Diagnostic LEDs (3)

Mounting and grounding screw
RJ45 connectors (2)
STO output to drive

Here are the FSPS-21 module details:

– STO outputs to the drive are located at the bottom, between the RJ45 connectors
– Two RJ45 connectors for PROFIsafe and PROFINET connections
– Status LEDs are mounted on the front of the module
– The module has one mounting / grounding screw located at the lower left corner of the
module. On the upper side of the module, there’s also a mechanical locking pin for the
module to secure the attachment.

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PROFIsafe safety functions module, FSPS-21
Module details, diagnostic LEDs

FSPS-21 has three different diagnostic LEDs: Host, Module and Net.
With the Host LED, the module indicates whether the connection to the control unit is OK or if
there’s an internal error in the module itself. Also, the state of the STO is indicated as long the
communication with the upper system is OK.
The Module LED indicates the state of the FSPS-21.
With the Net LED, the FSPS-21 indicates communication over Ethernet.

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PROFIsafe
FSPS-21

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PROFIsafe safety functions module
ACS580

ACS880

ACS880 ACS380
Multidrives

Build a PROFIsafe network with several drives

Possible to have different kinds of functional safety modules in the same network

FSPS-21 can be used with all safety PLCs that support PROFIsafe over the PROFINET
protocol.
As the FSPS-21 is supported by ACS380, 580 & 880 drives, it is possible to build
PROFIsafe/PROFINET networks where different types of drives are included, if needed.
It is of course possible to have an ACS880 with FSO-12 or -21 and FENA-21 in the same
PROFIsafe network.

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PROFIsafe for all-compatible drives
Why PROFIsafe?

Simplified control and coordination of multiple drives

through PROFIsafe over PROFINET

SIL3-/PLe-certified safety communication

Easier, simple wiring

FSPS-21
One wire to control drive and safety functionality

Can be part of bigger systems where a PLC controls the

system

Flexible for modifications  no need to change the wiring

Why choose a PROFIsafe-based solution?

PROFIsafe over PROFINET communication offers a safe, simple and easy way to control
and coordinate multiple drives.
With PROFIsafe, it’s possible to simplify the structure of the control system, as only one
wire is needed from the safety PLC.
This makes modifications easy, reduces installation and engineering, and adds flexibility
to the design of control systems where safety is integrated.

When using the FSPS-21 module, it is possible to control the drive, control safety and use
PC-tools through one wire.

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PROFINET I/O
FSPS-21

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MRP ring
Media Redundancy Protocol
PLC
• MRP = Media Redundancy Protocol (ring redundancy
protocol)
• Enables implementing a redundant PROFINET
communication through ring topology with fewer
external switches
• MRP increases the failure tolerance of the PROFINET
network Switch
• If communication is lost in one direction, it continues
in the other direction
• PLC or switch must have MRP ring manager capability
Drive Drive Drive Drive
• FSPS-21, FPNO-21 and FENA-21 are ring clients
• Max. 50 nodes per ring

With FSPS-21, it is possible to use the latest PROFINET features, such as Media
Redundancy Protocol (MRP).
With this ring protocol, it is possible to increase the fault tolerance of a PROFINET
network. If communication is lost in one direction (e.g. due to a fault in the wire, the
system can keep running through the second network cable.
To use MRP, the PLC and switches must also support this feature. The maximum amount
of drives in such a ring is 50.

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Shared Device

• With Shared Device, it is possible to have two separate PLC Safety PLC
PLC systems connected to the same drive with FSPS-21
• Helps with industry upgrades where the existing
control system is used but a safety control system with
a safety PLC is added
• E.g. an AC800 control system can be connected to
the same Switch
FSPS-21 as the safety PLC. No additional adapter is
needed.
• One slot in the drive is available for other needs.
• It is possible to increase system performance as the Drive Drive Drive Drive
”standard” PLC does not take care of safety.
• CPU usage is fully for process control

• The MRP ring feature and daisy chaining are possible

with Shared Device.

With the Shared Device feature, it is possible to control one drive with two separate
controllers.
By using this feature, it is possible to fully concentrate the CPU usage of the controller for
process control and then have a separate safety PLC in the system.
With this feature, it is also possible to add a safety PLC to the exisating system when
upgrading an existing system.
It’s also possible to mix MRP and daisy chaining with Shared Device, as the image shows.

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Tool network
For Drive composer pro Control system
- Drives are connected to the PC tool network via an
Ethernet adapter (FSPS-21, FENA-x1, FPNO-21)
PC – tool
- Ethernet switches and cables are used to connect
network Switch Safety PLC
FENAs together
- 100 nodes (drives) possible in the network

Capability Multi-drive Drive

Drive Drive
• In theory, 300 nodes in the same network is the
maximum.
• The practical limit is currently about 100 nodes.
Current recommendations for this solution:
- Full Drive composer pro features are available: • If only PROFIsafe control in the network: 100 nodes (drives)
- Configuration of drives • If PROFIsafe and PC-tool network: 60 nodes
- Monitoring of multiple drives • If PROFIsafe, PC-tool network and PROFINET(control): 40
- Custom parameter windows nodes
- Backing up the entire network
- Control traffic has higher priority in the network

It is possible to use the one-wire solution, where PC tool communication, control of

the drive and safety communication run through the same Ethernet cable.
In theory, it is possible to have 300 drives in the same network, but the current
practical limitation is about 100 drives. The number of drives in the same network
may need to be reduced if there’s a lot of high acyclic load (e.g. reading parameter
values or monitoring) in the network.

Through the PC-tool network, it is possible to configure and monitor the drives,
back up the entire network, and use custom parameter windows.

Current recommendations for this solution:

• If only PROFIsafe control in the network:100 nodes (drives)

• If PROFIsafe and PC-tool network: 60 nodes

• If PROFIsafe, PC-tool network and PROFINET (control): 40 nodes

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Separate PLCs for control and safety

- There can be separate PLC for the control purposes PLC Multi-drive Drive Drive Drive
(e.g. Rockwell PCL) and for safety purposes (e.g. ABB FBA 1
PLC) with PROFIsafe connection.
Safety PLC
FBA 2
- Drives are equipped with two different Fieldbus
modules. In each drive, in slot one (FBA 1) there can be
e.g. FEIP-21 for Ethernet/IP connection to the control
PLC, and FSPS-21 in slot two (FBA 2) for safety control.

It is also possible to control the drive via another Fieldbus e.g. with a Rockwell PLC
via Ethernet/IP and govern safety control for the drive with an ABB PLC via
PROFIsafe.
In this case, the drive must be equipped with two different Fieldbus modules. In
slot 1 of the drive, there could be an FEIP-21 for Ethernet/IP control, and in slot 2,
there could be an FSPS-21 for PROFIsafe.

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Certificates
FSPS-21

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Adding customer value with Drive-based Functional Safety
Safety functions are TÜV-certified & conform to the Machinery Directive
TÜV product & functional safety Certificates available at
Declaration of Conformity (EU) management system certifications
(Machinery Directive) IEC 61508, ISO 13849-1, IEC 62061, IEC http://new.abb.com/drives/f
marking 61800-5-2, usable in IEC 61511 systems unctional-safety

DoC FSM ACS880 FSPS-

+ STO 21

FSPS-21 has a TÜV certificate to prove that we fulfill all the necessary functional safety
standards: IEC 61800-5-2, 61508, 62061 and ISO 13849-1.
The declaration of conformity is a declaration that our module, together with the drives, fulfills all
applicable European standards and directives.
At ABB Drives, we also have a functional safety management (FSM) system, which is certified
by TÜV to make sure that our quality and processess related to functional safety are handled
correctly.

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Additional info
FSPS-21

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“How to” videos for FSPS-21

There two ”how to configure the FSPS-21” videos available.

The first video shows how to configure the FSPS-21 together with an ABB AC500-S
PLC

LINK TO THE VIDEO

The second video shows how to configure the FSPS-21 together with a Siemens PLC.

LINK TO THE VIDEO

There are also training videos about how to configure the FSPS-21 with ABB AC500-S and
Siemens PLCs. These videos can be found from the links and also from the ABB library.

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Functional safety training for Drive-based Functional Safety

G3850 - FSO safety functions module fundamentals, Internet course

G3851 - ACS880 functional safety configuration with FSO EXTERNAL
G3852 - Encoder safety functions with FSO and FSE safety encoder interface module
G3853 - ACS880 cabinet-built industrial drives - Safety functions with FSO module
G3854 - ACS880 cabinet-built industrial drives – FSO configuration
G3855 – PROFIsafe configuration
G3856 – ACS880 PROFIsafe configuration https://mylearning.abb.com/

G1110e – Drives Functional Safety Management - Awareness

G1111e – Drives Functional Safety - Technical Basics
G1112 - Drives Functional Safety - R&D INTERNAL
G1113 - Drives Functional Safety - Product Engineering
G1114 - Drives Functional Safety - Production
G1115 - Drives Functional Safety - Order-Based Engineering
G1116e - Drives Functional Safety - Service
G1117e - Drives Functional Safety - Sales & Product Management

Through the new ”my learning” training portal, it is possible to participate in other drive-
based functional safety training courses, which will give further information.
There are also training videos about how to configure the FSPS-21 with ABB AC-500-S and
Siemens PLCs. These videos can be found from the Drive-based Functional Safety
webpage.
http://new.abb.com/drives/functional-safety

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Thank you for viewing this presentation.

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