Danfoss VLT Safety Option MCB 150 User Manual Download

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MAKING MODERN LIVING POSSIBLE

Operating Instructions

Safety Option MCB 150/151

www.danfoss.com/drives

Summary of Contents for VLT Safety Option MCB 150

Page 1: ...MAKING MODERN LIVING POSSIBLE Operating Instructions Safety Option MCB 150 151 www danfoss com drives...

Page 2: ......

Page 3: ...ecification of Safety Functions 11 3 2 1 1 Performance Level PL and Safety Integrity Level SIL 11 3 2 2 Validation of Performance Level 11 3 2 3 Activation of Safety Functions 12 3 2 4 Simultaneous Ac...

Page 4: ...Errors 24 3 7 2 Compatibility between Safety and Frequency Converter Functions 24 4 Installation 25 4 1 Installing the Safety Option 25 4 1 1 Requirements for Safe Use 25 4 1 2 Protected Cable Instal...

Page 5: ...Servicing and Modifications 46 7 2 Repair 46 7 3 Replacing 46 7 3 1 Removing the Safety Option 46 7 3 2 Replacing the Safety Option 46 7 3 3 Copying Safe Parameter Set up 47 7 4 Commissioning Test 51...

Page 7: ...xplains the contents structure and specific order of this manual Chapter 2 Legal Information and Safety Provides information on the most important product features Chapter 4 Installation Explains how...

Page 8: ...angular position of a rotating component Installed on in a motor the encoder shows the angular position of the rotor Error Discrepancy between a computed observed or measured value or condition and th...

Page 9: ...ation for safely limited speed SO Safety Option SRECS Safety Related Electrical Control System IEC 62061 SRP CS Safety related parts of control systems EN ISO 13849 1 SS1 Safe Stop 1 Safety function i...

Page 10: ...G HIGH VOLTAGE Frequency converters contain high voltage when connected to AC mains input power Installation start up and maintenance should be performed by qualified personnel only Failure to perform...

Page 11: ...ucts may only be assembled installed programmed commissioned maintained and decommis sioned by persons with proven skills Persons with proven skills are qualified electrical engineers or persons who h...

Page 12: ...ets S37 output low This allows the operator to open the safety gate In speed monitor applications the safety output S37 is high for operation when the motor speed of the monitored device is below the...

Page 13: ...uator E g FC 302 Illustration 3 2 Sensor Logic Actuator Safety Chain 3 2 Functions 3 2 1 Specification of Safety Functions The standards require a specification of functional requirements The specific...

Page 14: ...other functions are active Safe Stop 1 has medium priority to the other safe functions Safely Limited Speed has the lowest priority If 2 Safe Stop 1 functions are active at the same time the function...

Page 15: ...safety option is designed for use in safety related applications It meets the requirements for safety functions in accordance with IEC 61800 5 2 regarding safe motion monitoring 3 2 8 MCT 10 Set up So...

Page 16: ...ors the controlled stop If a power outage or an error occurs a controlled stop is impossible Trigger the safety function Safe Torque Off after the stop to shut off the motor torque Refer to EN IEC 618...

Page 17: ...tion This function ensures that no torque generating energy can continue to affect a motor and prevents unintentional start ups WARNING If any external forces influence the motor axis e g suspended lo...

Page 18: ...uring that the system is also stopped before Safe Torque Off is activated If a fault occurs the frequency converter does not come to a stop It coasts after the time delay no matter of the speed of the...

Page 19: ...e speed is at zero speed limit Safe Torque Off is activated Safety function Safe Torque Off is activated when the configured limit value for the position error is exceeded A standstill threshold Zero...

Page 20: ...peed monitoring profile by a deceleration time and a tolerable speed Delta V Parameter Unit Range Default 42 47 Ramp Time s 0 1 3600 0 s 1 0 s 42 45 Delta V RPM 1 10000 RPM 120 RPM 42 46 Zero Speed RP...

Page 21: ...peed represents the maximum allowed frequency of the actual motor frequency If the motor frequency accelerates above that value the safety option enters external fault selected STO or SS1 Ramp and the...

Page 22: ...e ramp down times out If the system speed exceeds or is equal to the configured safe speed limit during Safely Limited Speed monitoring a Safely Limited Speed fault occurs and the safety option initia...

Page 23: ...annel input are not detected Therefore the cables of the channels must be routed separately to exclude short circuits NOTICE Routing of the sensor cables All proximity switch sensor encoder cables mus...

Page 24: ...nnected sensor on DI1 or DI2 or both is enabled via a reset the safety option can be switched on again This deactivates active safety functions or errors NOTICE First trip alarms displayed on the freq...

Page 25: ...state for at least 42 23 Stable Signal Time Input Signal 130BC317 10 DI1 DI2 Safety function Active Inactive Test pulse pattern Stable signal time Stable signal time Illustration 3 15 Filter for Suppr...

Page 26: ...he safety option or frequency converter activates the safety function Safe Torque Off The frequency converter coasts the motor Internal errors always result in a fault requiring a power cycle of the f...

Page 27: ...n read and follow the instructions 4 1 1 Requirements for Safe Use CAUTION Ensure that the installation and wiring are EMC compliant to avoid personal injury and damage to the product Refer to the gui...

Page 28: ...is 10 cm 6 Connect the control cables to safety option and relieve the cable by the enclosed cable strips Follow the guidelines in chapter 4 1 4 General Wiring Guidelines 130BT340 10 Illustration 4 3...

Page 29: ...erter terminal 37 NOTICE Control cables must be screened armoured See the section Earthing of Screened Control Cables in the VLT AutomationDrive Design Guide for detailed specifi cations Only screened...

Page 30: ...nel B 8 DI2 B Digital Input 2 B channel 9 ENC nB Encoder Channel B inverted 10 24 V Power output 11 GND Supply GND 12 S37 STO enable Table 4 1 Connector Pin Assignment MCB 150 E30BC325 11 MCB 150 Safe...

Page 31: ...Digital Input 2 B channel 9 GND Digital GND 10 24 V Power output 11 GND Supply GND 12 S37 STO enable Table 4 2 Connector Pin Assignment MCB 151 E30BC326 11 MCB 151 SafeOption SW ver xx xx OptionB 130...

Page 32: ...l transmission according to RS 485 standard must be used for data signals or track A and track B The wire cross section must in each individual case be chosen in compliance with the current consumptio...

Page 33: ...ximity switch as encoder feedback set 42 14 Feedback Type to 1 Without direction info 4 3 Application Examples 4 3 1 Connecting Safe Digital Inputs The following pages contain examples of connecting t...

Page 34: ...n An example of an unsafe condition could be the failure of the contact to a short circuit condition A switch with positive opening operation should be used to reduce the possibility of a failure of t...

Page 35: ...to configure safety functions that are wired up to the safety option inputs 2 Ensure that the device number serial number and order number of the safety option on the frequency converter matches the d...

Page 36: ...p to 10 s may elapse before the safety option is ready for operation 5 2 3 Safety Option Customisation LCP messages used to indicate the different states of the customisation processes LCP message Des...

Page 37: ...tion EN IEC 61508 EN IEC 62061 and EN ISO 13849 require that the final assembler of the machine validates the operation of the safety function with a commissioning test The commissioning tests for the...

Page 38: ...Plug in The control system passes the configuration to the respective safety option The feasibility of the configuration is checked when it is downloaded Further information on configuration and setti...

Page 39: ...e also reset If 42 31 Reset Source is set to 1 Drive Safe Reset 3 Safe Option Reset must be configured in 8 14 Configurable Control Word CTW NOTICE The frequency converter specific alarms are not rese...

Page 40: ...ption is in this state at each power up Bit 14 External failure Bit 14 0 No External failure is active Bit 14 1 External failure is active Bit 15 Safe function pending Bit 15 0 No Safe function pendin...

Page 41: ...atus 2 Bit 00 01 DI1 Safety Status Bit 00 01 00 Inactive Bit 00 01 01 Active Bit 00 01 10 Pending Bit 02 03 DI2 Safety Status Bit 00 01 00 Inactive Bit 00 01 01 Active Bit 00 01 10 Pending Bit 04 Blan...

Page 42: ...e Option are read only Refer to VLT AutomationDrive FC 302 Programming Guide for general information about usage of conversion index and data type General Parameter Set up Operating Instructions 40 Da...

Page 43: ...sed when gear mounted 4 u_int32 42 14 Feedback Type 0 With direction info 1 Without direction info 0 With direction info The feedback can be with or without direction information For TTL HTL encoder d...

Page 44: ...iour 0 Manual 1 Automatic 0 Manual In case of an activated safety function the safety option can either restart automatically or wait for a RESET signal from the user u_int8 42 3 General 42 30 Externa...

Page 45: ...peed that the safety option allows 67 u_int16 42 46 Zero Speed 1 600 RPM 10 RPM When this speed is reached the safety option activates the STO 67 u_int16 42 47 Ramp Time 0 1 3600 0 s 1 0 s Time to ram...

Page 46: ...O no u_int8 42 54 Ramp Down Time 0 1 3600 0 s 1 0 s Ramp down time for start ramp 1 u_int16 42 8 Status 42 80 Safe Option Status 0 4294967295 0 Shows the safety option status word as a hexadecimal val...

Page 47: ...9 Special 42 90 Restart Safe Option 0 No 1 Yes 0 No Possibility to restart option after internal failure without power cycling the frequency converter u_int8 Table 6 3 Safety Option Parameters Refer...

Page 48: ...e safety option see MCT 10 Set up Software Operating Instructions 2 Duplicate the existing device setting NOTICE The frequency converter generates an error message after removing the safety option How...

Page 49: ...or the duplicated safety option parameters Follow the guided sequence on the LCP display to transfer the safety option parameters to a safety option Verify that the correct safety parameter file is tr...

Page 50: ...130BD118 10 Safety Password Please enter the safety Password 1 1 0 RPM None 0000000 0 If password protection is enabled in 0 69 Password Protection of Safety Parameters enter the correct LCP copy para...

Page 51: ...ess Cancel to abort the customisation of the safety option A reset is required to finalise this procedure Table 7 1 LCP Copy Messages Mismatch of Safety Option Parameters Message Description 130BD115...

Page 52: ...ameters including the level 1 password 1 1 0 RPM 0 00A 130BD121 10 SO Data Confirmation Press OK to confirm commissioning test must be performed or CANCEL to abort 1 1 0 RPM 0 00A Decision box for con...

Page 53: ...llowing Secure the site in accordance with the regulations barrier warning signs etc The system may only be commissioned recommissioned by qualified personnel Refer to the information and specificatio...

Page 54: ...correctly on the frequency converter A commissioning test of the safety option must be performed in the following situations After the configuration of each machine After changing the safety option p...

Page 55: ...ng 5 Select Safe Torque Off while the frequency converter is running 6 Check the following The frequency converter coasts to zero speed The motor is braked and stopped by the mechanical brake if avail...

Page 56: ...stops within the delay time specified The motor is braked and stopped by the mechanical brake if available and configured The SS1 will end with an STO warning or alarm depending on configuration 7 De...

Page 57: ...tops within the delay time specified The motor is braked and stopped by the mechanical brake if available and configured The SS1 will end with an STO warning or alarm depending on configuration 7 Dese...

Page 58: ...o zero speed The motor is braked and stopped by the mechanical brake if available and configured The SS1 will end with an STO warning or alarm depending on configuration 7 Deselect Safe Stop 1 8 Check...

Page 59: ...nverter coasts to zero speed if Safe Torque Off is selected as fault reaction Run Safe Stop 1 if that is selected as fault reaction The motor is braked and stopped by the mechanical brake if available...

Page 60: ...nc Pending is displayed 9 Run the frequency converter The motor speed must be higher than the Safely Limited Speed selected if the machine allows this 10 Ensure that the correct frequency converter is...

Page 61: ...disposed of together with domestic waste It must be separately collected with electrical and electronic waste according to local and currently valid legislation Service and Repair Operating Instructi...

Page 62: ...onfiguration validated Green Permanent System OK input or output activated Yellow Flashing System OK configuration not yet validated Red Flashing Alarm Red Permanent Fatal error Table 8 2 LED Status I...

Page 63: ...Encoder Direction to the opposite value Decrease ramping time on frequency converter Try to run the system at e g 60 RPM If error nr 99 now occurs this is the reason Improve shielding of feedback cabl...

Page 64: ...ccordingly Increase 42 50 Cut Off Speed or decrease 42 51 Speed Limit to get a larger tolerance Red constant 71 Int fail speed limit SLSb Reaction STO See 70 See 70 Red constant 72 Internal failure MC...

Page 65: ...ification Extend discrepancy time on safe input tab in MCT 10 safe plug in 14 22 Operation Mode Red constant 76 Int Fail DI1 in PUST Reaction STO Safety input connected to DI1 has illegal signal level...

Page 66: ...tion First power cycle the frequency converter If the problem persists contact Danfoss Red constant 82 Internal failure safety option First power cycle the frequency converter If the problem persists...

Page 67: ...persists contact Danfoss Red constant 89 Internal failure safety option Perform a general reset of the safety option with the Administration button If the problem persists contact Danfoss Red constan...

Page 68: ...Danfoss Red constant 98 Int fail invalid customer file version Version of customisation file of safety option stored in EEPROM does not match the customisation file supported by the SW version of safe...

Page 69: ...ate assigned to DI1 and DI2 Red flashing cycle on 500 ms off 500 ms 116 Ext Fail SF activation Speed Suspension Reaction STO The frequency converter has been running below 120 RPM for more that 1 year...

Page 70: ...nd LED2 depends on Safety function state assigned to DI1 and DI2 Red flashing cycle on 500 ms off 500 ms 244 Ext Fail SF activation Speed Suspension Reaction SS1b See 116 See 116 Red flashing cycle on...

Page 71: ...start and Failure Acknowledge signal which is always required after a PUST and when a safety function gets released and is configured to be confirmed that the motor is able to run LCP message Descript...

Page 72: ...S 485 incremental encoders Input differential voltage range 7 to 12 V DC Input common mode voltage 12 to 12 V DC Input voltage logic 0 diff 200 mV DC Input voltage logic 1 diff 200 mV DC Input resista...

Page 73: ...Specifications Ground I O section Cable length 30 m screened or unscreened cable 30 m screened cable Cable cross sections Digital inputs output supply voltage 0 75 mm2 AWG 18 AEH without plastic coll...

Page 74: ...l SIL 2 SIL CL2 HFT IEC 61508 Hardware Fault Tolerance 1 Subsystem Classification Type B Probability of Dangerous Failure per Hour PFH 1 52 e 8 Probability of Dangerous Failure on Demand PFD 1 33 e 3...

Page 75: ...2 47 49 50 58 60 62 68 69 71 Response time 23 Risk assessment 8 11 RS 485 30 33 36 47 S Safe jog 20 Safe motion monitoring 13 Safe Stop 1 7 10 12 13 14 15 16 17 19 21 36 Safe Torque Off 10 12 14 15 16...

Page 76: ...ithout notice This also applies to products already on order provided that such alterations can be made without subsequential changes being necessary in specifications already agreed All trademarks in...

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