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STO AND SS1 SAFETY FUNCTIONS

vacon • 23

Local contacts: https://www.danfoss.com/en/contact-us/contacts-list/

Abbreviations or safety parameters definitions

SIL

Safety Integrity Level

PL

Performance Level

PFH

Probability of a dangerous random hardware Failure per Hour

Category

Designated architecture for a safety function (from EN ISO 13849-1:2006)

PFD

AVG

The average probability of (random hardware) failure on demand

T

M

Mission time

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Summary of Contents for OPTAF

Page 1: ...vacon nx ac drives optaf sto and atex option board user manual ...

Page 2: ......

Page 3: ...ample 3 OPTAF board with external safety relay module with or without reset for Safe Torque Off STO or EN 60204 1 stop category 0 26 3 4 4 Example 4 OPTAF board with external time delayed safety relay for Safe Stop 1 SS1 or EN 60204 1 stop category 1 27 3 5 Commissioning 28 3 5 1 General wiring instructions 28 3 5 2 Checklist for commissioning the OPTAF board 30 3 5 3 Parametrizing the drive for t...

Page 4: ...4 3 Maintenance 46 4 3 1 Fault diagnosis of thermistor function 46 NOTE You can download the English and French product manuals with applicable safety warning and caution information from http drives danfoss com knowledge center technical documentation REMARQUE Vous pouvez télécharger les versions anglaise et française des manuels produit contenant l ensemble des informations de sécurité avertisse...

Page 5: ...he manual 1 2016 C STO SS1 standard info corrected EC type examination STO SS1 certificate updated STO safety related data updated ATEX declaration of conformity added Other minor updates Throughout the manual 8 2017 D Updated ATEX certificate Updated EC declaration Changed information related to IP54 requirement in Chapters 1 and 2 Changed information related to programmable relays in Figure 1 an...

Page 6: ...d An adequate protection can be installation in an IP54 enclosure or the use of a drive with coated PCBs Motor Thermistor Over temperature protection according to ATEX Overtemperature detection using thermistor It can be used as a tripping device for ATEX certi fied motors The thermistor tripping function is certified by VTT according to ATEX directive 94 9 EC All safety functions of the OPTAF boa...

Page 7: ...ecified in EN 61800 5 2 2007 fulfils all of the relevant safety component requirements of EC Machinery Directive 2006 42 EC Notified body that carried out the EC type examination IFA Institute for Occupational Safety and Health of the German Social Accident Insurance Testing and Certification Body in BG PRÜFZERT Alte Heerstraße 111 D 53757 Sankt Augustin Germany European notified body Identificati...

Page 8: ...vacon 6 GENERAL Local contacts https www danfoss com en contact us contacts list ...

Page 9: ...GENERAL vacon 7 Local contacts https www danfoss com en contact us contacts list ...

Page 10: ...vacon 8 GENERAL Local contacts https www danfoss com en contact us contacts list ...

Page 11: ...GENERAL vacon 9 Local contacts https www danfoss com en contact us contacts list ...

Page 12: ...vacon 10 GENERAL Local contacts https www danfoss com en contact us contacts list ...

Page 13: ...s com en contact us contacts list 2 INSTALLATION OF THE OPTAF BOARD MAKE SURE THAT THE AC DRIVE IS SWITCHED OFF BEFORE AN OPTION OR FIELDBUS BOARD IS CHANGED OR ADDED A VACON NXP AC drive with IP54 enclosure B Remove the main cover C Open the cover of the control unit NOTE ...

Page 14: ...cable sealing grommets or glands for all cables in the drive The grommets or glands must be suitable for the type and amount of cables used and they shall fulfill IP54 requirements See the User Manual for hole sizes for the Power cables The hole size is PG21 28 3 mm for the control cables F Close the cover of the control unit and attach the main cover Before attaching the main cover check that the...

Page 15: ...he sticker on the board Figure 2 The layout of the control board VB00761 11052 emf Jumper X10 for selecting thermistor short circuit supervision 24V 24V 24V 24V SD1 SD2 Thermistor input Thermistor Input Thermistor active 4000 ohm After being active the fault can be reset if resistance is 2000 ohm Jumper wire X12 See Chapter 4 2 4 STO inputs two independent channels Programmable Relay NO NC Program...

Page 16: ... for designing safe machinery and for carrying out a risk assessment CAUTION The information in this manual provides guidance on the use of the safety functions that OPTAF option board provides together with VACON NXP control board This information is in compliance with accepted practice and regulations at the time of writing However the end product system designer is responsible for ensuring that...

Page 17: ...ated parts will not lead to the loss of the safety function This is done by disabling the gate driver signal outputs to the driver electronics The gate drive output signals control the IGBT mod ule When gate drive output signals are disabled the drive will not generate torque in the motor shaft See Figure 3 In larger drives the STO functionality extends to the power unit See Figure 4 If either of ...

Page 18: ...h the OPTAF board FR9 FR14 SD1 SD1 SD2 SD2 RO1 3 RO1 1 RO1 2 RO2 3 RO2 2 M 3 NXP CONTROL UNIT Control board OPTAF board slot B Control logic POWER UNIT Hardware STO 1 PWM control Thermistor Hardware STO 2 Atex Safety Function Relays only for operational use not part of the safety functions 11970_uk eps Enable Power unit logic Hardware STO 1 Hardware STO 2 PWM control ...

Page 19: ... 5 2 SS1 type c The Safe Stop 1 SS1 safety function consists of two safety related subsystems an external time delayed safety relay and the STO safety function These two subsystems combined compose the Safe Stop 1 safety function as shown in Figure 6 Figure 6 Safe Stop 1 SS1 safety function Time 0 Stop Motor deceleration Frequency factual Time delay Safe Torque Off STO 11054 emf Safe Stop 1 SS1 Ti...

Page 20: ...causes motor deceleration Figure 7 The connection principle of Safe Stop 1 SS1 See Chapter 3 5 5 concerning the parametrizing of Safe Stop 1 and Chapter 3 4 4 Example 4 for the wiring of Safe Stop 1 CAUTION The system designer user is responsible of understanding and setting the time delay of the safety relay due to the fact it is process machine dependent The time delay must be set to a greater v...

Page 21: ...ate STO diagnostics fault or STO may be activated The used dark test pulse duration should always be shorter than the specified minimum pulse withstanding duration Limits for the test pulse duration frequency and period are given in Table 3 The filtering time is hardware based and cannot be adjusted External dark test pulse filtering is included on VB00761 boards from revision J onwards See Chapte...

Page 22: ... the jumper X10 in OFF state The thermistor input operation and instructions are presented in Chapter 4 I O terminals on OPTAF Table 3 Pulse characteristics Pulse characteristics Dark test pulse Light test pulse Test pulse length 1 ms 24 V 1 ms 24 V Period 20 ms 20 ms Frequency 50 Hz 50 Hz CAUTION When using other connection than Connection example 1 with light test pulse function forbidden pulse ...

Page 23: ...een in different states for 5000 ms 24 VDC 24 VDC STO inactive Standard Control board VB00761 revision F and older all frame sizes Controlboard VB00761 revision G and newer FR4 FR8 Control boardVB00761 revision G and newer with new power units FR9 FR14 EN 61800 5 2 2007 SIL 2 PFH 2 98 x 10 9 hour Dual Channel Structure SIL 3 PFH 2 70 x 10 9 hour Dual Channel Structure SIL 3 PFH 3 4 x 10 9 hour Dua...

Page 24: ... a safety function of combined subsystems is the sum of all subsystems PFH values PFHSS1 PFHSafety Relay PFHNX STO 1 89 x 10 9 hour 2 70 x 10 9 hour 4 59 x 10 9 hour The result is within the requirements for SIL 2 or PL d PFH is even within the requirements for up to SIL 3 PL e IEC 61508 2000 Low Demand Mode SIL 2 PFDavg 2 61 x 10 4 TM 20 years Dual Channel Structure SIL 3 PFDavg 2 30 x 10 4 TM 20...

Page 25: ...ions or safety parameters definitions SIL Safety Integrity Level PL Performance Level PFH Probability of a dangerous random hardware Failure per Hour Category Designated architecture for a safety function from EN ISO 13849 1 2006 PFDAVG The average probability of random hardware failure on demand TM Mission time ...

Page 26: ... running will stop by coasting The drive will indicate A30 SafeTorqueOff When switch S1 is released contacts closed the drive returns to the ready state The motor can then be run with a valid start command F1 1 2 3 4 5 6 L1 L2 MAIN CIRCUIT L3 PE PE L1 L2 L3 U V W PE X10 2 7 PE PE PE W1 M1 M 3 U1 1 V1 W1 2 PE R1 SPEED REFERENCE S CCW CW W12 1r 2p 2s 1sh 2sh OPTA1 Basic I O SLOT A 1 10Vref 1 2 AIA1 ...

Page 27: ...med Release switch S1 contacts closed The hardware is now enabled but the drive continues to display the fault F30 SafeTorqueOff Acknowledge the releasing of switch by edge sensitive reset function The drive returns to the ready state Giving a valid start command will start running the motor NOTE For EN 60204 1 emergency stop according to stop category 0 use emergency stop button F1 1 2 3 4 5 6 L1...

Page 28: ...tation NOTE For EN 60204 1 emergency stop according to stop category 0 use emergency stop button Switch S1 in the figure can be replaced with the gate switch then only Safe torque off mode is required In normal operation both contacts are closed F1 1 2 3 4 5 6 L1 L2 MAIN CIRCUIT L3 L1 L2 L3 U V W PE X10 2 7 W1 M1 M 3 U1 1 V1 W1 2 PE R1 SPEED REFERENCE S CCW CW W12 1r 2p 2s 1sh 2sh OPTA1 Basic I O ...

Page 29: ...losed the drive returns to ready state The motor can then be run with a valid start command The external relay can be wired so that manual reset is required to reset the STO safety function More information regarding the safety relay module may be found from the safety relay datasheet F1 1 2 3 4 5 6 L1 L2 L3 L1 L2 L3 U V W PE X10 W1 M1 M 3 U1 1 V1 W1 2 PE MAIN CIRCUIT 04W12 1r 2p 2s 2sh 1sh R1 SPE...

Page 30: ...o the general wiring instructions for the specific prod uct where OPTAF is installed See wiring examples in the Figure 12 Figure 13 and Figure 14 If shielded cable is used the shield must be connected to the drive s lid PE using a ground ing clamp EN 60204 1 part 13 5 The voltage drop from supply point to load must not exceed 5 In practice due to electromagnetic disturbances the cable length shoul...

Page 31: ...eld to separate the STO input channels from each other as shown in Figure 15 Type For example one of the following 2x2x0 75mm2 18 AWG low voltage cable with two individually shielded twisted pairs 2x2x0 75mm2 18 AWG low voltage unshielded twisted pair cable two separate 2x0 75mm2 18 AWG shielded or unshielded twisted pair cables SAFETY ACTUATOR OPTAF CHANNEL 1 SW P 24V 24V OV OV SW M SD1 SD1 OPTAF...

Page 32: ... type Used STO input connection STO connection example 1 STO connection example 2 STO connection example 3 Undiagnosed safety actuator i e emergency stop button or relay contact No diagnostics Shielded X 200 m 200 m Unshielded X 30 m X Safety actuator with diagnosed outputs i e safety PLC Outputs diagnosed using e g dark test pulse light test pulse not used Shielded 200 m 200 m 200 m Unshielded 30...

Page 33: ...nction is used with Safe Torque Off STO or Safe Stop 1 SS1 it must be edge sensitive 5 The shaft of a permanent magnet motor might in an IGBT fault situation rotate up to 360 degrees pole of the motor Has it been ensured that the system designed in such a way that the this can be accepted 6 Have process requirements including deceleration time been consid ered for correct execution of Safe Stop 1 ...

Page 34: ...e and the external time delayed safety relay for Safe Stop SS1 safety function Safe Stop 1 requires setting of time delay on the external safety relay component Requirement The time delay setting needs to be greater than the deceleration time set in the drive Code Parameter Default Note P7 2 1 2 Start Up Prev Fault To start the motor operation after the STO safety func tion or a thermistor fault a...

Page 35: ...that the STO or SS1 safety functions are working properly by testing them before operating the system NOTE Before testing the STO or SS1 safety functions make sure that the checklist Table 7 is in spected and completed NOTE Concerning the SS1 safety function make sure by testing that the drive s stop by ramp func tion is working in accordance with the process requirements When the STO safety funct...

Page 36: ...ard might have to be removed from its slot After reconnecting the board ALWAYS make sure that the STO or SS1 safety functions are active and fully func tional by testing them See Chapter 3 5 6 Table 9 Internal variables of the drive for monitoring and logging Variable Source Type Description OPTAFStatus Firmware Shows internal status related to OPTAF option board B0 Safe Off active B1 Thermistor i...

Page 37: ...fault occurs when the SD inputs are in different state more than 5 sec onds Check the S1 switch Check the cabling to the OPTAF board Single hardware problem possible in either OPTAF board or VACON NXP control board 8 System Fault 31 Thermistor short circuit detected Correct the cabling Check the jumper for the thermistor short circuit supervision if thermistor function is not used and the thermist...

Page 38: ...ault 48 Parameter Expander boards SlotB Therm Trip HW is set to OFF even though the jumper wire X12 is not cut Correct the parame ter according to the jumper settings 8 System Fault 49 OPTAF is only compatible with NXP Remove the OPTAF board 8 System Fault 50 Hardware problem The fault only appears with SIL3 compatible con trol boards Change the NXP control board 8 System Fault 51 Hardware problem...

Page 39: ...he field of industry Maximum SIL capability of this function in the drive is SIL1 CAUTION The information in this manual provides guidance on the use of thermis tor function for protecting overheating of motors in explosive atmosphere This information is ensured to be correct and in compliance with accepted practice and regulations at the time of writing However the end product system designer is ...

Page 40: ...ty with the requirements of the Council directive for explosive atmospheres 94 9 EC of March 1994 until April 19th 2016 2014 34 EU from April 20th 2016 according to following standards EN ISO 13849 1 2006 Safety of machinery safety related parts of the control systems Part 1 General principles for design EN ISO 13849 2 2003 Safety of machinery safety related parts of the control systems Part 2 Val...

Page 41: ...VACON NXP AC drive with the OPTAF board SD1 SD1 SD2 SD2 RO1 3 RO1 1 RO1 2 RO2 3 RO2 2 NXP CONTROL UNIT Control board OPTAF board slot B POWER UNIT Thermistor Atex Safety Function Relays only for operational use not part of the ATEX certified thermistor function M 3 Hardware STO 1 PWM control Hardware STO 2 PWM control Control logic 11068 eps ...

Page 42: ...further heating up of the motor due to this is avoided The thermistor supervision circuit meets the requirements in the ATEX directive by acting directly on the STO safety function of the VACON NXP See Figure 16 and is thus providing a reliable software and parameter independent way of preventing the energy supply to the motor 11052 emf 24V 24V 24V 24V SD1 SD2 Jumper wire X12 See Chapter 4 2 4 Jum...

Page 43: ...1 section 7 2 9 The overtemperature is detected by hardware on OPTAF board See temperature versus resistance curve as in the figure below Table 12 OPTAF I O terminals Terminal Parameter reference on keypad and NCDrive Technical information 1 SD1 DigIN B 2 Isolated STO input 1 24 V 2 SD1 Virtual GND 1 3 SD2 DigIN B 3 Isolated STO input 2 24 V 4 SD2 Virtual GND 2 21 22 23 RO1 normal closed RO1 commo...

Page 44: ...con 42 THERMISTOR FUNCTION ATEX Local contacts https www danfoss com en contact us contacts list Figure 18 Typical characteristics of a motor protection sensor as specified in DIN 44081 DIN 440 11069 emf ...

Page 45: ...k for the corresponding warning or fault indication in the drive according to the parameter setting explained in Chapter 4 2 2 4 2 2 Parameter setting for ATEX function In case of overtemperature the drive modulation is disabled The drive will not anymore feed ener gy to the motor thus preventing further overheating of the motor See Figure 16 When drive is connected to the main power and if the mo...

Page 46: ...ate 4 2 3 Short circuit monitoring The thermistor inputs TI1 and TI1 are monitored for short circuit If a short circuit is detected the drive modulation is disabled within 20ms F8 system fault subcode 31 is generated When the short circuit has been removed the drive can be reset only after power recycle to the VACON NXP con trol board The short circuit monitoring can be enabled or disabled using t...

Page 47: ...tive start command is required after the drive returns to ready state a When OPTAF board parameter Start Up Prev is Fault the drive will generate a F26 Start Up Prev fault if start command is on when returning to ready state after the STO safety function or a thermistor fault has been active The drive can be started with an edge sensitive start command after fault reset b When OPTAF board paramete...

Page 48: ... Fault code Fault Subcode Possible cause Correcting measures 8 System Fault 30 STO inputs are in different state This fault occurs when the STO inputs are in different state more than 5 seconds Check the S1 switch Check the cabling to the OPTAF board Single hardware problem possible in either OPTAF board or VACON NXP control board 8 System Fault 31 Thermistor short circuit detected Correct the cab...

Page 49: ...wer 8 System Fault 48 Parameter Expander boards SlotB Therm Trip HW is set to OFF even though the jumper wire X12 is not cut Correct the parameter according to the jumper settings 8 System Fault 49 OPTAF is only compatible with NXP Remove the OPTAF board 8 System Fault 50 Hardware problem The fault only appears with SIL3 compatible control boards Change the NXP control board 8 System Fault 51 Hard...

Page 50: ...Document ID DPD00891F Rev F Sales code DOC OPTAF 10 DLUK Vacon Ltd Member of the Danfoss Group Runsorintie 7 65380 Vaasa Finland www danfoss com ...

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