Danfoss MCB 112, FC 202, FC 302, FC 102 Operating guide

MAKING MODERN LIVING POSSIBLE

Operating Instructions

VLT® PTC Thermistor Card MCB 112

VLT® HVAC Drive FC 102 • VLT® AQUA Drive FC 202
VLT® AutomationDrive FC 302

vlt-drives.danfoss.com

Contents Operating Instructions

Contents

1 Introduction

1.1 Purpose of the Manual

1.2 Additional Resources

1.3 Document and Software Version

1.4 Products Covered

1.5 Functional Overview

1.5.1 Intended Use 3

1.5.2 Foreseeable Misuse 4

1.5.3 Thermal Motor Protection 4

1.5.4 ATEX ETR Thermal Monitoring 4

1.5.5 Tripping Function 4

1.5.6 Safe Separation 4

1.5.7 Safe Disconnection Principle 4

1.6 Motor Requirements

1.6.1 Motor Limits and Rules 5

1.6.2 Additional Motor Requirements 5

1.7 Approvals and Certications

3
3
3
3
3
3

5

5

1.8 Symbols, Abbreviations, and Conventions

2 Safety

2.1 Safety Symbols

2.2 Qualied Personnel

2.3 Safety Precautions

3 Installation

3.1 Safety Instructions

3.2 Installation of Sensor Circuit Wires

3.3 Installation of the VLT® PTC Thermistor Card MCB 112

4 Commissioning

4.1 Operation and Maintenance

4.1.1 Monitoring Sensor Resistance 12

4.2 Parameter Set-up

4.2.1 Alarm Handling 13

4.3 Parameter Set-up for Ex-e and Ex-n Motors

6

7
7
7
7

9
9
9

10

12
12

13

14

4.3.1 Maximum Current 14

4.3.2 Maximum Current Limit 14

4.3.3 Minimum Motor Frequency 14

4.3.4 Maximum Motor Frequency 15

4.3.5 Minimum Switching Frequency 15

MG33V302 Danfoss A/S © 01/2015 All rights reserved. 1

Contents

VLT® PTC Thermistor Card MCB 112

4.3.6 Disable Protection Mode 15

4.3.7 Safe Torque O Functionality 15

5 Application Examples

6 Maintenance and Troubleshooting

6.1 Maintenance

6.2 Troubleshooting

6.2.1 Alarm/Warning Code List 19

6.2.2 Description of Alarm Word, Warning Word, and Extended Status Word 19

7 Technical Specications

7.1 Mains Supply

7.2 Control Inputs and Outputs

7.3 Ambient Conditions

7.4 Other Specications

7.5 Safety Characteristics of the Built-in MCB 112

Index

17

19
19
19

21
21
21
21
22
22

23

2 Danfoss A/S © 01/2015 All rights reserved. MG33V302

Introduction Operating Instructions

1 Introduction

1

1

1.1 Purpose of the Manual

This manual provides information for safe installation and
commissioning of VLT® PTC Thermistor Card MCB 112 used
with a Danfoss VLT® frequency converter with Safe Torque

O (STO). The manual is intended for use by qualied
personnel only.

VLT® PTC Thermistor Card MCB 112 is also referred to as
MS 220 DA.

The operating instructions are intended for use by
qualied personnel. Read and follow the operating
instructions to use the frequency converter safely and
professionally, and pay particular attention to the safety
instructions and general warnings. Keep these operating
instructions available with the frequency converter at all
times.

VLT® is a registered trademark.

1.2 Additional Resources

This manual is targeted at users already familiar with the
VLT® frequency converters. It is intended as a supplement

to the manuals and instructions available for download at
vlt-drives.danfoss.com/Support/Technical-Documentation/.
Read the instructions shipped with the frequency
converter and/or frequency converter option before
installing the unit, and observe the instructions for safe
installation.

1.3

Document and Software Version

1.4

Products Covered

The VLT® PTC Thermistor Card MCB 112 is available for the
following types of frequency converters:

VLT® HVAC Drive FC 102.

•

VLT® AQUA Drive FC 202.

•

VLT® AutomationDrive FC 302.

•

1.5 Functional Overview

1.5.1 Intended Use

The VLT® PTC Thermistor Card MCB 112 is intended to:

Protect electrical motors against inadmissible

•

heating due to overload.
Protect explosion-protected motors in explosive

•

atmospheres caused by gases, vapours, or mists,
Zone 1 and Zone 2, and/or in explosive
atmospheres caused by dust, Zone 21 and Zone

22. Refer to marking G for Zone 1 and Zone 2.
Refer to marking D for Zone 21 and Zone 22.

All functions in the MCB 112 serve to protect both non­explosive-protected motors and explosive-protected
motors in regular operation and in case of failure.

The VLT® PTC Thermistor Card MCB 112 is designed in
accordance with EN 60947-8 (VDE 0660 part 0302). Only
connect PTC thermistor sensors according to DIN 44081
and 44082 (EN 60947-8).

This manual is regularly reviewed and updated. All
suggestions for improvement are welcome. Please send
suggestions via email to
[e-mail], including a
reference to the document version. Table 1.1 shows the
document version and the changes applied.

Edition Remarks

MG33V3xx Replaces MG33V2xx.

Editorial changes.

Now covering the complete system.

Table 1.1 Document Version

MG33V302 Danfoss A/S © 01/2015 All rights reserved. 3

NOTICE

The VLT® PTC Thermistor Card MCB 112 is only functional
if it is built into the frequency converter. The option
cannot be used as a stand-alone.

MS 220 DA / MCB112

Code no.: 130B1137

Motor protection inside

See manual

for additional instruction

PTB 14 ATEX 3012U

CAUTION:

II (2) D [Ex tb][Ex tc]

II (2) G [Ex e] [Ex d] [Ex n]

ε

130BE103.10

Introduction

VLT® PTC Thermistor Card MCB 112

1

1.5.1.1 Markings of the Frequency
Converter

A sticker is delivered with the option as spare part or with
the frequency converter to signify ATEX certication. Apply
this sticker to the front of the frequency converter in
which the ATEX module is integrated. The sticker indicates
that the ATEX module is installed in the frequency
converter.

Illustration 1.1 Label to Apply to Frequency Converter

Foreseeable Misuse

1.5.2

Any use not expressly approved by Danfoss constitutes
misuse. This also applies to failure to comply with the
specied operating conditions and applications.

according to DIN 44081 or 44082, the MCB 112 oers
ATEX-approved monitoring of the motor temperature.
Alternatively, an external ATEX-approved PTC protection
device can be used.

1.5.4 ATEX ETR Thermal Monitoring

NOTICE

The ATEX ETR thermal monitoring function only applies
to Ex-e and Ex-n motors and is only available for VLT
AutomationDrive FC 302 frequency converters.

The FC 302 with
equipped with an ATEX ETR thermal monitoring function
for operation of Ex-e motors according to EN 60079-7 and
Ex-n motors according to EN 60079-15. Combined with an
ATEX-approved PTC monitoring device like MCB 112, the
installation does not need an individual approval from an
approbated organisation, that there is no need for
matched pairs.

The feature makes it easier to apply Ex-e and Ex-n motors
instead of the more expensive, larger, and heavier Ex-d
motors. The use of Ex-e and Ex-n motors is possible by
ensuring that the frequency converter limits the motor
current to prevent the motor from heating up.

Tripping Function

1.5.5

rmware version V6.3x or higher is

®

Danfoss assumes no liability of any sort for damage attrib­utable to improper use.

Only operate with explosion-protected 3-phase motors
which are built, tested and labelled separately for
frequency converter use.

WARNING

EXPLOSION DANGER

Zone 0 and Zone 20 are not applicable to electric
motors.
To avoid explosion, only use motors in:

Zone 1/21.

•

Zone 2/22.

•

1.5.3 Thermal Motor Protection

According to ATEX Directive 94/9/EC and Standard EN
60079-14, motor overload protection is a requirement.
The MCB 112 monitors the temperature in the motor
windings with an ATEX-approved motor overload
protection device. If there is a critical temperature level or
a malfunction, switch o the motor. If the frequency
converter is equipped with 3–6 PTC thermistors in series

The MCB 112 includes a tripping stage for PTC thermistor
sensors with safe potential separation of supply voltage
from ground. The tripping function switches o the +24 V
DC directly at terminal 37 on the frequency converter.

The PNP logic output terminal X44/10 signals the status in
case of failure. The MCB 112 works according to the
closed-circuit principle. The device trips in case of short
circuit or line interruption.

Safe Separation

1.5.6

The PTC thermistor circuit (T1, T2) has a safe separation of
low-voltage electric circuits PELV, see chapter 3.2 Instal-
lation of Sensor Circuit Wires.

1.5.7

Safe Disconnection Principle

The Safe Torque O function disables the control voltage
of the power semiconductors or the frequency converter
output stage. Disabling the control voltage prevents the
inverter from generating the voltage required to rotate the
motor.

4 Danfoss A/S © 01/2015 All rights reserved. MG33V302

Frequency Converter

Logic
Out

Control Card

Potentially explosive

atmosphere

PTC-Sensors

3~ Ex-Motor

Safe Channel T37

Safe Stop
T37

T1

TP TP

T2

+24 V

PTC Thermistor Card
MCB 112

Non-explosive hazard zone

91
92
93

96
97
98

Converter module

130BE102.10

DI

Introduction

Illustration 1.2 Block Diagram of the System

Operating Instructions

1.6 Motor Requirements

1.6.1 Motor Limits and Rules

For every certied motor with increased safety, the
manufacturer supplies a data list including limits and rules.
During planning, installation, commissioning, operation,
and service, respect the limits for:

Minimum switching frequency.

•

Maximum current.

•

Minimum motor frequency.

•

Maximum motor frequency.

•

Furthermore, respect the following:

1.6.2

Additional Motor Requirements

The Ex-e motor must be approved for operation in
hazardous zones (ATEX Zone 1/21, ATEX Zone 2/22) in
combination with frequency converters. The motor must
be certied for the particular hazardous zone.

The Ex-n motor must be approved for operation in
hazardous zones (ATEX Zone 2/22) in combination with
frequency conveters. The motor must be certied for the
particular harzardous zone.

NOTICE

The motor can be placed in Zone 1/21 or 2/22 according
to motor approval. The frequency converter must always
be installed outside of the hazardous zone.

Only operate explosion-protected 3-phase motors

•

with frequency converters, if the motors are built,
tested, approved, and labelled separately for this
mode.

When the usage of the motor and its thermal

•

protective device are approved for frequency
converter operation, use the MCB 112 for each
ignition protection system for all motor types. For
motors of Ex-e and Ex-n-type ignition protection,
which are OEM-approved for frequency converter
operation in Ex-harzardous areas, consider and
use the requested limitations in the frequency
converter’s ATEX ETR thermal monitoring settings.

The necessary parameters and conditions can be

•

found on the nameplate or the documentation of
the motor. To prevent prohibited temperatures,
the motors are equipped as standard with
thermal winding protection, which has to be
evaluated by a suitable device like MCB 112. The
motors must not be operated as a group drive.

1.7

Approvals and Certications

1

1

MG33V302 Danfoss A/S © 01/2015 All rights reserved. 5

Do not exceed the maximum allowable ratio

•

between frequency converter size and motor size.
The typical value is I

Consider all voltage drops from the frequency

•

converter to the motor. If the motor is running
with lower voltage than listed in the U/f charac­teristics, current might increase and cause an
alarm.

Multi-motor applications are not allowed. Only

•

connect 1 motor to the frequency converter.

≤2xI

VLT, n

m,n

.

Certication number:
PTB 14 ATEX 3012U

Certicates and declarations of conformity are available.
Contact a local Danfoss partner.

Introduction

VLT® PTC Thermistor Card MCB 112

1

1.8 Symbols, Abbreviations, and

Conventions

Abbreviation Description

ETR Electronic thermal relay.
LCP Local control panel.
NC Not connected.
PNP Positive negative positive (transistor).
TNF Nominal response temperature.

Table 1.2 Abbreviations

AbbreviationReference Description

ATEX ATEX Directive

94/9/EC

HFT EN IEC 61508 Hardware fault tolerance: HFT=n

PDS/SR EN IEC

61800-5-2

PFD EN IEC 61508 Average probability of failure on

SFF EN IEC 61508 Safe failure fraction [%]; percentage

SIL EN IEC 61508

EN IEC 62061

STO EN IEC

61800-5-2

SRECS EN IEC 62061 Safety-related electrical control

ATmosphere EXplosibles

means that n+1 faults could cause a
loss of the safety function.
Power drive system (safety-related).

demand, value used for low­demand operation.

of safe failures and dangerous
detected failures of a safety function
or a subsystem related to all failures.
Safety integrity level.

Safe Torque O.

system.

Table 1.3 Abbreviations Related to Functional Safety

Conventions

Numbered lists indicate procedures.
Bullet lists indicate other information and description of
illustrations.
Italicised text indicates:

Cross-reference.

•

Link.

•

Parameter name.

•

6 Danfoss A/S © 01/2015 All rights reserved. MG33V302

Safety Operating Instructions

2 Safety

2.1 Safety Symbols

The following symbols are used in this manual:

WARNING

Indicates a potentially hazardous situation that could
result in death or serious injury.

CAUTION

Indicates a potentially hazardous situation that could
result in minor or moderate injury. It can also be used to
alert against unsafe practices.

NOTICE

Indicates important information, including situations that
can result in damage to equipment or property.

2.2 Qualied Personnel

The products must only be assembled, installed,
programmed, commissioned, maintained, and decommis­sioned by persons with proven skills. Persons with proven
skills:

Are qualied electrical engineers, or persons who

•

have received training from qualied electrical
engineers and are suitably experienced to
operate devices, systems, plant, and machinery in
accordance with the general standards and
guidelines for safety technology.

Are familiar with the basic regulations concerning

•

health and safety/accident prevention.
Have read and understood the safety guidelines

•

given in this manual and also the instructions
given in the operating instructions of the
frequency converter.

Have a good knowledge of the generic and

•

specialist standards applicable to the specic
application.

Users of PDS(SR) are responsible for:

Hazard and risk analysis of the application. In EN

•

ISO 12100, risk assessment is dened as an
overall process comprising a risk analysis and a
risk evaluation.

Ensuring that the qualied personnel has

•

experience with working in ATEX areas according
to Directive 99/92/EC (also known as the ATEX
Workplace Directive).

Identifying safety functions required, and

•

allocating SIL to each of the functions.
Other subsystems and the validity of signals and

•

commands from those subsystems.
Designing appropriate safety-related control

•

systems (hardware, software, parameterisation,
and so on).

Protective measures

Safety engineering systems must only be installed

•

and commissioned by qualied and skilled
personnel.

Install the frequency converter in an IP54 cabinet

•

as per IEC 60529, or in an equivalent
environment. In special applications, a higher IP
degree may be necessary.

Ensure short-circuit protection of the cable

•

between terminal 37 and the external safety
device according to ISO 13849-2 table D.4.

When external forces inuence the motor axis (for

•

example suspended loads), additional measures
(for example a safety holding brake) are required
to eliminate hazards.

2.3

Safety Precautions

WARNING

EXPLOSION HAZARD

Using the VLT® PTC Thermistor Card MCB 112 in areas
with explosive gas and/or dust atmosphere may lead to
death, personal injury, or property damage. To avoid the
risk, adhere to the following:

Always provide the MCB 112 with a pressurised

•

enclosure according to EN 60079-1 (Explosive
atmospheres - Part 1: Equipment protection by
ameproof enclosures “d”).

Observe national safety rules and regulations

•

for prevention of accidents, as well as the
European Standard EN 60079-14 (Explosive
atmospheres - Part 14: Electrical installations
design, selection, and erection).

Only

•

•

qualied personnel (see
chapter 2.2 Qualied Personnel) is allowed to
install, connect, and commission the MCB 112.

Ensure that the motor thermal protection
switches o the motor directly, via the STO
function, or by using the ATEX ETR thermal
monitoring function.

2 2

MG33V302 Danfoss A/S © 01/2015 All rights reserved. 7