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Summary of Contents for optbj

Page 1: ...safety manual sto and atex option board optbj ac drives vacon 100 hvac vacon 100 flow vacon 100 industrial ...

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Page 3: ...6 1 General wiring instructions 29 6 2 Wiring examples 32 6 3 Parameterization of STO functionality 36 6 4 Checklist for commissioning the OPTBJ board 37 6 5 Testing the Safe Torque Off STO or Safe Stop 1 SS1 safety functions 38 7 Maintenance 39 7 1 Faults related to the Safe Torque Off STO or Safe Stop 1 SS1 safety functions 39 8 Thermistor function ATEX 41 8 1 Technical data 45 8 1 1 Functional ...

Page 4: ...strie Service GmbH NB0035 Am Grauen Stein 51105 Köln Germany The following standards and or technical specifications referenced below were used EN 61800 5 2 2007 Adjustable speed electrical power drive systems Part 5 2 Safety requirements Functional EN 61800 5 1 2007 only for LV Directive compliance Adjustable speed electrical power drive systems Part 5 2 Safety requirements Electrical thermal and...

Page 5: ...Approvals vacon 5 Local contacts https www danfoss com en contact us contacts list 1 ...

Page 6: ...1 vacon 6 Approvals Local contacts https www danfoss com en contact us contacts list ...

Page 7: ...Approvals vacon 7 Local contacts https www danfoss com en contact us contacts list 1 ...

Page 8: ...1 vacon 8 Approvals Local contacts https www danfoss com en contact us contacts list ...

Page 9: ...Approvals vacon 9 Local contacts https www danfoss com en contact us contacts list 1 ...

Page 10: ... Added new chapters 4 1 4 4 5 3 2 5 3 3 and 5 3 4 Added wiring examples in chapter 6 1 Changed cable recommendation information in chapter 6 1 Added new chapter 6 3 Corrected the notes related to edge sensitive start command in chapter 6 2 the chapter was moved here from end of chapter 5 Discrepancy time of STO inputs increased from 50 ms to 500 ms for board revision D Change affects chapters 5 3 ...

Page 11: ...e 2 cannot be guaranteed use the IP54 protection class Safe Stop 1 SS1 The SS1 safety function is realized in compliance with type C of the drives safety standard EN 61800 5 2 Type C The PDS SR initiates the motor deceleration and initiates the STO function after an application specific time delay The SS1 safety function has been designed for use in accordance with the following standards EN 61800...

Page 12: ...a dangerous control voltage present even when VACON 100 family AC drive is disconnected from mains 2 NOTE Incompatible boards cannot be installed on VACON 100 family AC drives Boards that are compatible for VACON 100 family AC drives have two codings that enable the placing of the board see above one for VACON 100 family compatibility A and another for the slot specific placing B M4x55 11573_00 90...

Page 13: ...nto slot E Close the inner cover NOTE See Chapter 4 2 for the jumper settings 4 If shielded cable is used ground the shield of the OPTBJ cable to the frame of the drive by using the grounding clamp for control cable included in the delivery of the drive NOTE If shielded cable is used grounding must be done according to best prac tice E 3041A_00 11574A_uk Grounding clamp for control cable ...

Page 14: ...he OPTBJ cable protection class IP21 NOTE Cut the opening on the side of the slot E 6 Remount the AC drive cover and run the cable as shown in picture NOTE When planning the cable runs remember to keep the distance between OPTBJ cables and the motor cable at a minimum of 30 cm It is rec ommended to route the OPTBJ cables away from the power cables as shown in the picture 11576_00 11572_uk OPTBJ ca...

Page 15: ...hat the board is of revision D Some features may be introduced or changed during board updates Figure 2 The board identification sticker on the OPTBJ board 1 2 3 4 25 26 28 29 3038A_uk X23 X10 STO JMP Thermistor short circuit supervision On Off Jumper for selecting thermistor short circuit supervision Jumper for STO board activation Place here the 3 pin jumper from the control board STO inputs Rel...

Page 16: ...the three pin jumper from the drive control board and place it to the OPTBJ board jumper X10 See the next chapter for more information NOTE If there are problems with the jumpers see chapter 7 1 Jumper X23 short circuit supervision 3039A_uk Jumper X10 STO board activation STO board activated Jumper has to be placed here when OPTBJ is installed in the drive Take the jumper from the control board Sh...

Page 17: ...acts https www danfoss com en contact us contacts list 4 4 3 STO jumper on the VACON 100 family AC drive Figure 4 STO jumper location on VACON 100 family AC drive Open the main cover and the inner cover to reveal the jumper 3049A_00 STOJMP ...

Page 18: ...o be separated from PE when the OPTBJ board is installed Do not do this before consulting the Danfoss support personnel contact the Danfoss local contacts at http drives danfoss com danfoss drives local contacts If the jumper is cut at least 1 mm of wire from X15 needs to be re moved to ensure isolation CAUTION Cutting this jumper should be done only when it is required by the sys tem After the ju...

Page 19: ... be correctly incorporated into the entire system The entire system must be designed in compliance with all relevant standards within the field of industry Standards such as EN12100 Part 1 Part 2 ISO 14121 1 provide methods for designing safe ma chinery and for carrying out a risk assessment CAUTION The information in this manual provides guidance on the use of the safety functions that OPTBJ opti...

Page 20: ... is achieved by disabling the drive modulation The drive modulation is dis abled through two independent paths controlled by STO1 and STO2 so that a single fault in any of the safety related 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 module When gate drive o...

Page 21: ...gure 7 STO principle with OPTBJ board and VACON 100 family control board MR12 STO1 STO2 RO 3 3 VACON 100 CONTROL UNIT Control board OPTBJ board slot E MASTER POWER UNIT SLAVE POWER UNIT Thermistor Atex Safety Function Atex Safety Function Hardware STO 1 Hardware STO 2 Hardware STO 1 Hardware STO 2 11654A_uk ...

Page 22: ...61800 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 9 Figure 9 Safe Stop 1 SS1 safety function Time 0 Stop Motor deceleration Frequency factual Time delay Safe Torque Off STO 11578_uk Safe Stop 1 SS...

Page 23: ...ization of Safe Stop 1 Figure 10 The connection principle of Safe Stop 1 SS1 CAUTION The system designer user is responsible for understanding and setting the time delay of the safety relay as it is process machine dependent The time delay must be set to a greater value than the deceleration time of the drive The motor deceleration time is process machine dependent The stop function of the drive n...

Page 24: ... inputs on OPTBJ If the input voltage specific values for dark test pulse durations are exceeded the drive may indicate 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 5 The filtering time is hardware based and ca...

Page 25: ...d setting the jumper X23 in OFF state The thermistor input operation and instructions are presented in chapter 8 1 If 230VAC is used as control voltage from the output relays the control circuitry must be powered with a separate isolation transformer to limit short circuit current and overvoltage spikes This is to prevent the welding on the relay contacts Table 5 Pulse characteristics Pulse charac...

Page 26: ...he ATEX input has no effect on the relay output Table 7 STO function truth table VSTO1 VSTO1 VSTO2 VSTO2 STO state 0VDC 0VDC STO active 24VDC 0VDC STO diagnostic fault and STO activation Fault is activated after inputs have been in different states for 500 ms 0VDC 24VDC STO diagnostic fault and STO activation Fault is activated after inputs have been in different states for 500 ms 24VDC 24VDC STO ...

Page 27: ...ts for support and details Table 8 Safe Torque Off STO safety related data MR4 MR10 MR12 EN 61800 5 2 2007 SIL 3 PFH 4 12x10 10 hour HFT 1 SIL 3 PFH 4 30x10 10 hour HFT 1 EN 62061 2005 SIL CL 3 PFH 4 12x10 10 hour HFT 1 SIL CL 3 PFH 4 30x10 10 hour HFT 1 EN ISO 13849 1 2006 PL e MTTFd 1700 years DCavg medium Category 3 PL e MTTFd 700 years DCavg medium Category 3 IEC 61508 2010 High Demand Mode SI...

Page 28: ...lated data from user manual and certificate VACON 100 STO safety related data MR4 MR10 SubsystemSafetyRelay SubsystemVACON100STO Safe Stop 1 SS1 safety related data When the two subsystems are combined the maximum safety integrity level or performance level reached is the level of the lower subsystem SIL 2 and PL d The PFH value for a safety function of combined subsystems is the sum of all subsys...

Page 29: ...e voltage drop from supply point to load must not exceed 5 In practice due to electromagnetic disturbances the cable length should be limited to to max 200 m when using shielded cable and to max 50 m when using unshielded cable In a noisy environment the length of the cable could still be less in order to avoid unwanted trip ping Using unshielded cables is not allowed with some STO input configura...

Page 30: ...arate the STO input channels from each other as shown in Figure 14 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 OPTBJ CHANNEL 1 SW P 24V 24V OV OV SW M STO1 STO1 OPTBJ CHANNEL...

Page 31: ... actuator Cable 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 ...

Page 32: ... the following sequence is performed Release the switch S1 contacts closed The hardware is now enabled and the drive returns to ready state Giving a valid start command starts running the motor NOTE According to EN 60204 1 Safety of machinery Electrical equipment of machines the re setting of the emergency stop request e g releasing of emergency stop button must not restart the drive NOTE The VACO...

Page 33: ...tive reset function The drive returns to the ready state Giving a valid start command starts running the motor NOTE According to EN 60204 1 Safety of machinery Electrical equipment of machines the re setting of the emergency stop request e g releasing of emergency stop button must not restart the drive NOTE The VACON 100 default application software uses edge sensitive start as a default start com...

Page 34: ...ay is resetted STO Fault action needs to be parameterized as Alarm If STO Fault action is pa rameterized as Fault also the drive needs to be reset to allow ready state See application manual for related parameters To start the motor operation again following sequence is performed Release the switch S1 contacts closed The hardware is now enabled and the drive returns to ready state An alarm indicat...

Page 35: ...ery Electrical equipment of machines the re setting of the emergency stop request e g releasing of emergency stop button must not restart the drive NOTE The VACON 100 default application software uses edge sensitive start as a default start command With the edge sensitive start command disactivating the STO does not cause immediate start NOTE For EN 60204 1 emergency stop according to stop categor...

Page 36: ...or the related parameters Table 10 Parameter description for STO fault parameter Index Parameter Min Max Default ID Description P3 9 1 14 INDUS TRIAL FLOW STO Fault No Action Fault Coast Fault Coast 775 No Action Activating STO causes motor to stop by coasting and Not ready state Drive returns to Ready state as soon as STO is deactivated No indication of STO activation is displayed Alarm Activatin...

Page 37: ...instruc tions in this manual 9 Has the STO input wiring been done according to examples 10 Have process requirements including deceleration time been consid ered for correct execution of Safe Stop 1 SS1 safety function and are the corresponding settings done 11 Is there a risk of conductive contamination e g conductive dust in the environment 12 If pollution degree 2 cannot be guaranteed IP54 prot...

Page 38: ...roperly by testing them before operating the system 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 NOTE If the STO safety function is used in a low demand operating mode it must be tested period ically at least once a year When the STO safety function is activated a code Fault 30 SafeTorque...

Page 39: ...ty configuration 500 STO jumper is installed on the control board Remove the STO jumper from the control board See ch 3 1 and 3 1 1 30 Safety configuration 501 More than one OPTBJ option board detected in the drive Only one OPTBJ board is sup ported by the drive Remove other OPTBJ boards from the drive except from slot E 30 Safety configuration 502 OPTBJ option board installed to a wrong slot OPTB...

Page 40: ...p change the OPTBJ board Should the fault re occur con tact the distributor near to you 30 Safety diagnostics 522 Atex thermistor short circuit Check the connection of the Atex thermistor Check the thermistor Restart the drive If the restart does not help change the OPTBJ board Should the fault re occur con tact the distributor near to you 30 Safety diagnostics 523 Problem occured in internal safe...

Page 41: ...must be designed in compliance with all relevant standards within the field of industry NOTE The special conditions required for safe use X in the certificate number This function can be used with Exe Exd and ExnA type of motors In case of Exe and ExnA motors the end user has to confirm that the installation of the measurement circuit is done according to area classification For example in the Exe...

Page 42: ...or 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 Validation EN 60079 14 2007 Electrical apparatus for e...

Page 43: ...contacts list 8 Figure 15 Thermistor function principle in VACON 100 family AC drive with the OPTBJ board MR4 10 STO1 STO2 RO 3 VACON 100 CONTROL UNIT Control board OPTBJ board slot E POWER UNIT Thermistor Atex Safety Function Atex Safety Function Hardware STO 1 Hardware STO 2 11575B uk ...

Page 44: ...re 16 STO principle with OPTBJ board and VACON 100 family control board MR12 STO1 STO2 RO 3 3 VACON 100 CONTROL UNIT Control board OPTBJ board slot E MASTER POWER UNIT SLAVE POWER UNIT Thermistor Atex Safety Function Atex Safety Function Hardware STO 1 Hardware STO 2 Hardware STO 1 Hardware STO 2 11654A_uk ...

Page 45: ...TI1 of the OPTBJ board The optocoupler isolates the thermistor inputs from the control board potential If 230VAC is used as control voltage from the output relays the control circuitry must be powered with a separate isolation transformer to limit short circuit current and overvoltage spikes This is to prevent the welding on the relay contacts Figure 17 Typical characteristics of a motor protectio...

Page 46: ...hermistor input on OPTBJ board pe riodically typically once a year For testing activate the thermistor functionality e g remove Atex thermistor plug from the OPTBJ board The drive enters to fault state and indicates fault 29 Atex thermistor fault subcode 280 8 2 1 General wiring instructions The thermistor connection must be done using a separate control cable It is not allowed to use wires belong...

Page 47: ...Document ID DPD00470E Rev E Sales code DOC OPTBJ DLUK Vacon Ltd Member of the Danfoss Group Runsorintie 7 65380 Vaasa Finland www danfoss com ...

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