Danfoss vacon 100 industrial, vacon 100 flow, vacon 100 hvac, optbj User guide
vacon
sto and atex option board
®
100 industrial
vacon
®
100 flow
vacon® 100 hvac
ac drives
optbj
safety manual
vacon • 3
TABLE OF CONTENTS
Document: DPD00470G
Release date : 28102020
1. Approvals............................................................................................................... 4
2. General ................................................................................................................ 10
2.1 References .............................................................................................................................. 11
3. Installation of OPTBJ board ................................................................................. 12
4. OPTBJ board layout.............................................................................................. 15
4.1 Identifying board revision........................................................................................................ 15
4.2 OPTBJ board jumpers............................................................................................................. 16
4.3 STO jumper on the VACON® 100 family AC drive .................................................................. 17
4.4 Cuttable jumper to separate control ground from PE ........................................................... 18
5. STO and SS1 safety functions ............................................................................... 19
5.1 Safe Torque Off (STO) principle .............................................................................................. 20
5.2 Safe Stop 1 (SS1) Principle ..................................................................................................... 22
5.3 Technical details ..................................................................................................................... 24
5.3.1 Response times....................................................................................................................... 24
5.3.2 Input voltage levels ................................................................................................................. 24
5.3.3 External dark test pulse filtering capability ........................................................................... 24
5.3.4 External light test pulse filtering capability ........................................................................... 25
5.3.5 Connections............................................................................................................................. 25
5.3.6 Relay output ............................................................................................................................ 26
5.3.7 Safety-related data according to the standard ...................................................................... 27
6. Commissioning .................................................................................................... 29
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 description ............................................................................................................ 45
8.1.2 Hardware and connections ..................................................................................................... 45
8.1.3 Atex function ........................................................................................................................... 45
8.1.4 Short circuit monitoring.......................................................................................................... 46
8.2 Commissioning ....................................................................................................................... 46
8.2.1 General wiring instructions .................................................................................................... 46
8.2.2 Fault diagnosis of thermistor function ................................................................................... 46
NOTE! You can download the English and French product manuals with applicable safety,
warning and caution information from https://www.danfoss.com/en/service-and-support/.
REMARQUE Vous pouvez télécharger les versions anglaise et française des manuels produit
contenant l’ensemble des informations de sécurité, avertissements et mises en garde
applicables sur le site
Local contacts: https://www.danfoss.com/en/contact-us/contacts-list/
https://www.danfoss.com/en/service-and-support/.
vacon • 4 Approvals
Date Issued by Date Approved by
15-04-2016 Signature
Name: Antti Vuola
Title: Head of Standard Drives
15-04-2016 Signature
Name: Timo Kasi
Title: VP, Design Center Finland and Italy
Danfoss only vouches for the correctness of the English version of this declaration. In the event of the declaration being translated into any other
language, the translator concerned shall be liable for the correctness of the translation.
ID No: DPD01856 Revision No: A Page
1 of 1
Danfoss A/S
DK-6430 Nordborg
Denmark
CVR nr.: 20 16 57 15
Telephone: +45 7488 2222
Fax: +45 7449 0949
EU DECLARATION OF CONFORMITY
Danfoss A/S
Vacon Ltd
declares under our sole responsibility that the
Product name Vacon OPTBJ option board to be used with Vacon 100 family products
Product identification 70CVB01380
Product Safety Functions Safe Torque Off (Specified in EN 61800-5-2)
fulfils all of the relevant safety component requirements of EC Machinery Directive 2006/42/EC.
Notified body that carried out the EC type examination:
TÜV Rheinland Industrie 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
energy
- EN 61800-3:2004/A1:2012 (only for EMC Directive compliance)
Adjustable speed electrical power drive systems, Part 3: EMC requirements and specific test methods
- EN ISO 13849-1:2008 + AC:2009
Safety of machinery - Safety-related parts of control systems –, Part 1: General principles for design
- EN 62061:2005 + AC:2010
Safety of machinery - Functional safety of safety-related electrical, electronic and programmable electronic
control systems
- IEC 61508 Parts 1-7:2010
Functional safety of electrical/electronic/programmable electronic safety-related systems
- EN 60204-1:2006 + A1:2009 + AC:2010 (in extracts)
Safety of machinery – Electrical equipment of machines – Part 1: General requirements
- EN 61326-3-1:2008
Electrical equipment for measurement, control and laboratory use – EMC, Part 3-1: Immunity requirements
for safety-related systems and for equipment intended to perform safety-related functions (functional safety).
1. A
PPROVALS
1
Local contacts: https://www.danfoss.com/en/contact-us/contacts-list/
Approvals vacon • 5
Local contacts: https://www.danfoss.com/en/contact-us/contacts-list/
1
vacon • 6 Approvals
1
Local contacts: https://www.danfoss.com/en/contact-us/contacts-list/
Approvals vacon • 7
Local contacts: https://www.danfoss.com/en/contact-us/contacts-list/
1
vacon • 8 Approvals
1
Local contacts: https://www.danfoss.com/en/contact-us/contacts-list/
Approvals vacon • 9
Local contacts: https://www.danfoss.com/en/contact-us/contacts-list/
1
vacon • 10 General
2. G
ENERAL
This document covers OPTBJ option board 70CVB01380 (141X4029) revision D (or newer).
Table 1. Version history of the manual
Date Revision Updates
10/2020 G
• Updated EC Type-Examination Certificate
NOTE! Designing of safety-related systems requires special knowledge and skills. Only qualified
persons are permitted to install and set up the OPTBJ board.
This document covers the OPTBJ option board 70CVB01380 (141X4029) functionality together with
VACON® 100 family Control board 70CVB01582 (141X4153).
The OPTBJ option board together with VACON® 100 family control board provides the following
safety functions with VACON® 100 family products.
The following safety-related abbreviations and expressions have been used in this manual:
SIL
PL
PFH
Category
MTTF
d
DC
avg
PFD
avg
T
M
Safety
actuator
OSSD
Safety Integrity Level
Performance Level
Probability of a dangerous random hardware Failure per Hour
Designated architecture for a safety function (from EN ISO 13849-1:2006)
Mean time to dangerous failure
Average diagnostic coverage
Average probability of (random hardware) failure on demand
Mission time
Device that controls the safety-related signal lines. Can be, for example, emergency button,
safety PLC, safety relay.
Output Signal Switching Device, i.e. switch that controls the signal lines between actuator and
the drive's signal input.
2
Safe Torque Off (STO)
The hardware based 'Safe Torque Off' safety function prevents the drive from generating torque on
the motor shaft. The STO safety function has been designed for use in accordance with the following
standards:
• EN 61800-5-2 Safe Torque Off (STO) SIL3
• EN ISO 13849-1 PL"e" Category 3
• EN 62061: SILCL3
• IEC 61508: SIL3
• The function also corresponds to an uncontrolled stop in accordance with the stop category 0, EN
60204-1.
• The STO safety function has been certified by TÜV Rheinland
NOTE! The STO function is not the same as a prevention of unexpected start-up function. For fulfilling those
requirements, additional external components are required according to appropriate standards and application requirements. Required external components may be for example:
• Appropriate lockable switch
• A safety relay providing a reset function
NOTE! The safety functions of OPTBJ do not comply with Emergency Switching Off according to EN 60204-1.
NOTE! Do not use the STO function as a standard stop function of the drive.
Local contacts: https://www.danfoss.com/en/contact-us/contacts-list/
General vacon • 11
13006.emf
NOTE! In an IGBT fault situation, the shaft of a permanent magnet motor can rotate up to 180 degrees around
the pole of the motor.
NOTE! If the pollution degree 2 cannot be guaranteed, use the IP54 protection class.
CAUTION! The OPTBJ board and its safety functions do not electrically isolate the
drive output from the mains supply. If electrical work is to be carried out on the
drive, the motor or the motor cabling, the drive has to be completely isolated
from the mains supply, for example, using an external supply disconnecting
switch. See, for example, EN60204-1 Chapter 6.5.
Safe Stop 1 (SS1)
The SS1 safety function is realized in compliance with type C of the drives safety standard EN 618005-2 (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 61800-5-2 Safe Stop 1 (SS1) SIL2
• EN ISO 13849-1 PL"d" Category 3
• EN 62061: SILCL2
• IEC 61508: SIL2
• The function also corresponds to a controlled stop in accordance with the stop cat. 1, EN 60204-1.
Motor Thermistor Over temperature protection (according to ATEX)
Overtemperature detection using thermistor. It can be used as a tripping device for ATEX certified
motors.
The thermistor tripping function is certified by VTT* according to ATEX directive 94/9/EC.
All safety functions of the OPTBJ board are described in this manual.
* VTT = Technical Research Centre of Finland
2.1 References
VACON® 100 family Installation and Application manuals are downloadable at
https://www.danfoss.com/en/service-and-support/.
Local contacts: https://www.danfoss.com/en/contact-us/contacts-list/
2
vacon • 12 Installation of OPTBJ board
M4x55
11573_00
9000.emf
3040A_00A B
3. I
Open the cover of the AC drive.
1
NSTALLATION OF
OPTBJ
BOARD
The relay outputs and other I/O-terminals may have 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).
3
Local contacts: https://www.danfoss.com/en/contact-us/contacts-list/
Installation of OPTBJ board vacon • 13
E
3041A_00
11574A_uk
Grounding clamp for
control cable
Open the inner cover to reveal the option board slots and install the OPTBJ board
into slot E. Close the inner cover.
NOTE! See Chapter 4.2 for the jumper settings!
3
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 practice.
Local contacts: https://www.danfoss.com/en/contact-us/contacts-list/
3
vacon • 14 Installation of OPTBJ board
11576_00
11572_uk
OPTBJ
cables
Unless already done for the other control cables,
cut free the opening on the AC drive cover for the
OPTBJ cable (protection class IP21).
NOTE: Cut the opening on the side of the slot E!
5
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 recommended to route the OPTBJ cables away from
the power cables as shown in the picture.
6
3
Local contacts: https://www.danfoss.com/en/contact-us/contacts-list/
OPTBJ board layout vacon • 15
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
Relay output
for STO function
Thermistor Input:
Thermistor active > 4000 ohm.
After being active, the fault can
be reset if resistance is < 2000 ohm
STO1+
STO1STO2+
STO2-
TI1+
TI1-
11855_00
4. OPTBJ
BOARD LAYOUT
4.1 Identifying board revision
The revision of OPTBJ board can be identified by checking the revision letter on the matrix bar code
sticker. Revision letter is written after the board type code. For example, '70CVB01380 D' indicates
that the board is of revision D. Some features may be introduced or changed during board updates.
Local contacts: https://www.danfoss.com/en/contact-us/contacts-list/
Figure 1. OPTBJ board layout
Figure 2. The board identification sticker on the OPTBJ board
4
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