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
vacon • 16 OPTBJ board layout
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.
Short circuit supervision ON
Short circuit supervision OFF
STO board not activated
= Factory default
4.2 OPTBJ board jumpers
There are two pin headers for jumpers on the OPTBJ option board. The jumper settings are described below:
To activate the OPTBJ board, you must take 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!
Figure 3. OPTBJ board jumpers
4
Local contacts: https://www.danfoss.com/en/contact-us/contacts-list/
OPTBJ board layout vacon • 17
3049A_00
STO JMP
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.
Local contacts: https://www.danfoss.com/en/contact-us/contacts-list/
4
vacon • 18 OPTBJ board layout
11856_00
X15
13006.emf
4.4 Cuttable jumper to separate control ground from PE
Figure 5.Location of cuttable jumper X15
Normally when the OPTBJ board is installed on the drive, the AC drive's control ground is connected
to PE (Protective Earth, drive's frame) through the OPTBJ board. Without the OPTBJ board, the control ground is connected to PE through high impedance. In some systems, the control ground may
need to 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 removed to ensure isolation.
CAUTION! Cutting this jumper should be done only when it is required by the system. After the jumper is cut, the drive's internal +24VDC can be used for external
safety devices if fault exclusion in wiring 'Short circuit of any conductor to an
exposed conductive part or earth or to the protective bonding conductor' according to EN ISO 13849-2 can be achieved.
4
Local contacts: https://www.danfoss.com/en/contact-us/contacts-list/
STO and SS1 safety functions vacon • 19
13006.emf
5. STO
The safety functions of the OPTBJ board, such as the technical principle and data, wiring examples
and commissioning, will be described in this chapter.
NOTE! The use of STO, SS1 or other safety functions does not itself ensure safety. An overall risk
evaluation is required in order to make sure that the commissioned system is safe. Safety devices
like the OPTBJ board must 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 machinery and for carrying out a risk assessment.
CAUTION! The information in this manual provides guidance on the use of the
safety functions that OPTBJ option board provides together with VACON® 100
family 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 the system is safe and in compliance with relevant
regulations.
AND
SS1
SAFETY FUNCTIONS
Local contacts: https://www.danfoss.com/en/contact-us/contacts-list/
5
vacon • 20 STO and SS1 safety functions
STO1
+
STO2
-
RO
=
3~
VACON 100 CONTROL UNIT
Control board
OPTBJ board, slot E
POWER UNIT
Thermistor
Atex S afety
Functi on
Atex S afety
Functi on
Hardware
STO 1
Hardware
STO 2
11575B_uk
5.1 Safe Torque Off (STO) principle
The STO safety function of the OPTBJ board allows the drive output to be disabled so that the drive
cannot generate torque in the motor shaft. For STO, the OPTBJ board has two separate, galvanically
isolated inputs STO1 and STO2.
NOTE! To allow the drive to go to ready state, a voltage of +24V must be connected between the input terminals for both STO input channels. See chapter 5.3.5 for details.
The STO safety function is achieved by disabling the drive modulation. The drive modulation is disabled 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 output signals are disabled, the drive will not generate torque in the motor
shaft. See Figures 6 and 7.
5
Figure 6.STO principle with OPTBJ board and VACON® 100 family control board MR4-10
Local contacts: https://www.danfoss.com/en/contact-us/contacts-list/
STO and SS1 safety functions vacon • 21
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
Figure 7.STO principle with OPTBJ board and VACON® 100 family control board MR12
Local contacts: https://www.danfoss.com/en/contact-us/contacts-list/
5
vacon • 22 STO and SS1 safety functions
Time
0
Stop
Motor
deceleration
Frequency
f
actual
Time delay
Safe Torque Off (STO)
11578_uk
Safe Stop 1 (SS1)
Time Delayed Safety Relay Vacon 100 Safe Torque Off (STO)
+
Subsystem
Safety Relay
Subsystem
STO
11579_uk
5.2 Safe Stop 1 (SS1) Principle
After a safe stop command the motor starts decelerating and SS1 safety function initiates the STO
after a user set time delay.
Figure 8. The principle of Safe Stop 1 (EN 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
5
Local contacts: https://www.danfoss.com/en/contact-us/contacts-list/
STO and SS1 safety functions vacon • 23
M
Switch
Safety Relay
with timer
Vacon 100
control
Basic I/O
Digital input
OPTBJ board
STO channel 1
STO channel 2
Time
delay
Power Unit
Ramp stop
STO1
STO2
11577A_uk
13006.emf
13006.emf
Figure 10 shows the connection principle of Safe Stop 1 safety function, as specified in figure 8.
• The time delayed safety relay outputs are connected to the STO inputs.
• A separate digital output from the safety relay is connected to a general digital input of the
VACON® 100 family AC drive. The general digital input must be programmed to execute the
drive stop command and initiates the drive stop function without a time delay (must be set to
"stop by ramp") and causes motor deceleration. If the SS1 behavior of Figure 8 is required
then it must be ensured that the ramp stop is activated when the stop signal is received. It is
the responsibility of the system designer to verify this. See Chapter 6.2 for the wiring and
parametrization 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
* In case of a single fault the drive may not ramp down but is only put to STO mode after the configured time delay.
the drive*. The motor deceleration time is process/machine dependent.
• The stop function of the drive needs to be correctly set for the process/
machine. Activating the SS1 safety function must execute the configured
stop in the drive. In the VACON® 100 default application software it is rec-
ommended to use the "Quick Stop" functionality for this purpose.
CAUTION! The control place must be set according to the application requirements.
Local contacts: https://www.danfoss.com/en/contact-us/contacts-list/
5
vacon • 24 STO and SS1 safety functions
5.3 Technical details
5.3.1 Response times
Table 2. STO response times
De-
activation
time
Safety function
Activation
time
Safe Torque Off (STO) < 20 ms 500 ms
5.3.2 Input voltage levels
STO inputs fulfill the requirements for standard operating ranges for Type 2 digital inputs (current
sinking), defined by IEC 61131-2 (2007). Reversed polarity applied on STO input terminals does not
cause disabling of STO function.
The STO inputs of OPTBJ are OSSD tolerant. The operation of OPTBJ is not interfered by test pulses
that are generated to the STO lines by the connected safety actuator as long as the test pulses fulfill
certain requirements. See chapters 5.3.3 and 5.3.4 for details.
Table 3. Safe input data
Technical item or function Minimum Typical Maximum
Input Voltage (logic 1) 11 V 24 V 30 V
Input Voltage (logic 0) -3 V 0 V 5 V
Input Current (logic 1) 4.5 mA 7.5 mA 8 mA
Input Current (logic 0) 2.0 mA
Input Resistance 2.5 kΩ
Galvanic Isolation Yes
Short circuit protected Yes
Active -> Inactive Debounce time 4 ms 9 ms
Allowed discrepancy time of physical inputs 500 ms
5
5.3.3 External dark test pulse filtering capability
To recognize the short circuits from STO lines to power supplies or ground, some safety PLCs test
their outputs by pulsing the output from high to low level for short periods of time when STO is disabled. The pulses are known as 'dark test pulses'. To prevent these test pulses from causing false
fault indications, these dark test pulses are filtered out by STO inputs on OPTBJ. If the input voltagespecific 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 cannot be adjusted. External
dark test pulse filtering is included on OPTBJ boards from revision D onwards. See chapter 4.1 for
identifying the board revision.
Table 4. External dark test pulse filtering capability
Dark test pulse filtering capability Minimum Typical Maximum
STO input voltage: 11 V 0 ms 0 ms 1 ms
STO input voltage: 24 V 4 ms 4 ms 7 ms
STO input voltage: 30 V 5 ms 6 ms 9 ms
Local contacts: https://www.danfoss.com/en/contact-us/contacts-list/
STO and SS1 safety functions vacon • 25
13006.emf
Table 5. Pulse characteristics
Pulse characteristics Dark test pulse Light test pulse
Test pulse length < 4 ms (24 V) < 4 ms (24 V)
Period > 20 ms > 20 ms
Frequency < 50 Hz < 50 Hz
5.3.4 External light test pulse filtering capability
To verify the switching capabilities of STO lines' switches, some safety actuators test their outputs
by pulsing the output from low to high level for short periods of time when STO is enabled. The pulses are known as 'light test pulses'. Allowed pulse characteristics are introduced in Table 5 in Chapter 5.3.3.
To prevent the test pulses from causing false STO disactivation commands or false fault indications,
the used connection must not create current path through STO inputs. Only connection example 1
is allowed. See the connection examples in chapter 6.1. Only one switch is allowed to be tested at a
time.
CAUTION! When using other connection than "Connection example 1" with light
test pulse function, forbidden pulse structure or by testing both switches (SW P &
SW M) simultaneously, the drive may enter ready state even if STO should be activated. This may cause unintentional rotation of the motor shaft. See the connection examples in chapter 6.1.
5.3.5 Connections
In addition to the STO inputs, the board contains also a thermistor input. If the thermistor input is
not used, it must be disabled. The thermistor input is disabled by making a short circuit to the terminals and setting the jumper X23 in "OFF" state. The thermistor input operation and instructions
are presented in chapter 8.1.
Table 6. OPTBJ I/O terminals
Terminal Technical information
1 STO1+ Isolated STO input 1, +24V
2 STO1- Virtual GND 1
3 STO2+ Isolated STO input 2, +24V
4 STO2- Virtual GND 2
25 RO1 Relay output 1 (NO) *
Switching capacity:
• 24VDC/8A
26 RO2
28 TI1+
29 TI1-
• 250VAC/8A
• 125VDC/0.4A
Min. switching load: 5V/10mA
Thermistor input; R
trip
> 4.0 kΩ (PTC)
* 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.
Local contacts: https://www.danfoss.com/en/contact-us/contacts-list/
5
vacon • 26 STO and SS1 safety functions
13006.emf
13006.emf
Table 7. STO function truth table
V
- V
STO1+
STO1-
0VDC 0VDC STO active
24VDC 0VDC
0VDC 24VDC
24VDC 24VDC STO inactive
V
STO2+
- V
STO2-
STO state
STO diagnostic fault and STO activation. Fault is activated after
inputs have been in different states for >500 ms.
STO diagnostic fault and STO activation. Fault is activated after
inputs have been in different states for >500 ms.
5.3.6 Relay output
When the STO function is active, the relay output is closed. When the STO function is inactive the
relay output is open. When STO function has detected a non-resettable diagnostics fault the relay
output toggles at a frequency of one hertz.
NOTE! The ATEX input has no effect on the relay output.
CAUTION! The relay output is intended only for diagnostics of the STO function.
CAUTION! The relay output is a non-safety-related functionality.
5
Local contacts: https://www.danfoss.com/en/contact-us/contacts-list/
STO and SS1 safety functions vacon • 27
5.3.7 Safety-related data according to the standard
Table 8. Safe Torque Off (STO) safety-related data *
MR4 - MR10 MR12
EN 61800-5-2:2007
EN 62061:2005
EN/ISO 13849-1:2006
IEC 61508:2010,
SIL 3
PFH = 4.12x10
HFT = 1
SIL CL 3
PFH = 4.12x10
HFT = 1
PL e
MTTFd =1700 years
DC
avg
Category 3
SIL 3
PFH = 4.12x10
-10
-10
= medium
-10
/hour
/hour
/hour
SIL 3
PFH = 4.30x10
HFT = 1
SIL CL 3
PFH = 4.30x10
HFT = 1
PL e
MTTFd =700 years
DC
avg
Category 3
SIL 3
PFH = 4.30x10
-10
-10
= medium
-10
/hour
/hour
/hour
High Demand Mode
IEC 61508:2010,
Low Demand Mode
HFT = 1
SIL 3
PFD
(TM)= 3.59x10-5
AVG
TM = 20 years
HFT = 1
HFT = 1
SIL 3
PFD
(TM)= 3.76x10-5
AVG
TM = 20 years
HFT = 1
* The values in the table above are worst case values and they are fulfilled with all board revisions.
If more detailed information is needed, contact Danfoss local contacts (http://drives.danfoss.com/
danfoss-drives/local-contacts/) for support and details.
Local contacts: https://www.danfoss.com/en/contact-us/contacts-list/
5
vacon • 28 STO and SS1 safety functions
Safe Stop (SS1) safety-related data
NOTE! The following chapter is only an informative example of combining products.
The SS1 safety function consists of two subsystems with different safety-related data.The subsystem consisting of the time delayed safety relay is manufactured, for example, by PHOENIX CONTACT. The following types are available from this manufacturer:
• PSR-SCP-24DC/ESD/5X1/1X2/300 or
• PSR-SPP-24DC/ESD/5X1/1X2/300
See manufacturer user manual for more information regarding the time delayed safety relay.
PSR-SC/PP-24DC/ESD/5X1/1X2/300 safetyrelated data from user manual and certificate:
VACON® 100 STO safety-related data (MR4-MR10):
IEC 61 508
EN 62061
DIN EN/ISO 13849-1
PFH
Subsystem
SafetyRelay
SIL 2
SIL CL 2
PL d
Category 3
1.89•10-9 /hour
Safe Stop 1 (SS1) safety-related data:
EN 61800-5-2
EN 62061
IEC 61508
DIN EN/ISO 13849-1
PFH
+
EN 61800-5-2
EN 62061
IEC 61508
DIN EN/ISO 13849-1
PFH
Subsystem
SIL 2
SIL CL 2
SIL 2
PL d
Category 3
2.31•10-9 /hour
VACON100STO
SIL 3
SIL CL 3
SIL 3
PL e
Category 3
4.12•10
-10
/hour
5
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 subsystems PFH values.
PFH
SS1
= PFH
Safety Relay
+ PFH
VACON100 STO
= 1.89•10-9 /hour + 4.12•10
-10
/hour = 2.31•10-9 /hour
• The result is within the requirements for SIL 2 and PL d.
Local contacts: https://www.danfoss.com/en/contact-us/contacts-list/
Commissioning vacon • 29
SAFETY ACTUATOR
OPTBJ
CHANNEL 1
SW P
+24V
OV
SW M
STO1+
STO1-
OPTBJ
CHANNEL 2
STO2+
STO2-
11851_uk
6. C
NOTE! The use of STO, SS1 or other safety functions does not itself ensure safety. Always make
sure that the safety of the entire system is confirmed.
NOTE! The user is responsible for excluding faults in the external wiring.
OMMISSIONING
6.1 General wiring instructions
• The wiring should be done according to the general wiring instructions for the specific product where OPTBJ is installed. See wiring examples in the figures 11, 12 and 13.
• If shielded cable is used, the shield must be connected to the drive's lid (PE) using a grounding 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 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 tripping.
• Using unshielded cables is not allowed with some STO input configurations. Also some STO
input connection options are not allowed to be used with certain safety actuator types. See
Table 9 for details.
• The +24V power supply used for safety actuators may come from control board (e.g. drive's
control connector pins 6 & 7) or it may also be external, earth fault and short circuit protected power supply.
Local contacts: https://www.danfoss.com/en/contact-us/contacts-list/
Figure 11. STO connection example 1
6
vacon • 30 Commissioning
SAFETY ACTUATOR
OPTBJ
CHANNEL 1
SW P
+24V
+24V
OV
OV
SW M
STO1+
STO1-
OPTBJ
CHANNEL 2
STO2+
STO2-
11852_uk
SAFETY ACTUATOR
OPTBJ
CHANNEL 1
SW P
+24V
+24V
SW P
STO1+
STO1-
OPTBJ
CHANNEL 2
STO2+
STO2-
OV
11853_uk
Figure 12. STO connection example 2
Cable recommendation:
See Table 9 for connections where shielded cable is required. In cases where the shield is marked
as being required, use the shield to separate the STO input channels from each other as shown in
Figure 14.
6
Type
Figure 13. STO connection example 3
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.
Local contacts: https://www.danfoss.com/en/contact-us/contacts-list/
Commissioning vacon • 31
Individual pair Overall shield
(Optional)
Pair shield
Cable jacket
11860_uk
Figure 14. Structure of cable with two individually shielded twisted pairs
Table 9. Recommended maximum cable lengths
Used STO input connection
Safety actuator type
Undiagnosed safety actuator
(i.e. emergency stop button or
relay contact)
Safety actuator with diagnosed
outputs (i.e. safety PLC)
Diagnostics on safety
actuator
No diagnostics
Outputs diagnosed using
e.g. dark test pulse,
light test pulse not used
Outputs diagnosed using
light test pulse
Cable type
Shielded X 200 m 200 m
Unshielded X 30 m X
Shielded 200 m 200 m 200 m
Unshielded 30 m 30 m X
Shielded 200 m X X
Unshielded 30 m X X
STO
connection
example 1
STO
connection
example 2
STO
connection
example 3
X = Not recommended due to causes of electromagnetic disturbances, safety actuator configuration or behavior
in failure situations.
Local contacts: https://www.danfoss.com/en/contact-us/contacts-list/
6
vacon • 32 Commissioning
F1
12345
6
L1 L2
MAIN CIRCUIT
L3
PE
PE
L1 L2 L3
U V W
PE
2
7
PE
PE
PE
W1
M1
M
3
~
U1
1
V1 W1
2
PE
R1
SPEED REFERENCE
S
CCW
CW
W12
1sh 1r 2sh 2p 2s
Basic I/O
1
+10Vref
1
2
AI1+
2
3
AI1
3
OPTBJ
SLOT E
1
STO1+
2
STO1
S1
11
12
W10
1r 2r1b 2b
S6
START
13
14
4
AI2+
4
5
AI2
5
6
24Vout
6
7
GND
7
3
STO2+
4
STO2
21
22
S7
STOP
11
12
8
DI1
8
9
DI2
9
10
DI3
10
11
CM
11
25
RO1 C
26
RO1 NO
28
TI1+
12
24Vout
12
13
GND
13
14
DI4
14
15
DI5
15
X23
OFF
29
TI1
16
DI6
16
17
CM
17
18
AO1+
18
19
AO/GND
19
30
+24Vin
20
PE
Safe torque off
+24V
0V
A
RS485BRS485
21 22
AO1
RS485
U
U
U
ON
OFF
I
I
I
AI2
AI1
Short circuit and earth
fault protected supply
ON OFF DGND
X10
Installed
3044B_UK.eps
6.2 Wiring examples
The examples in this chapter show the basic principles for wiring OPTBJ board. Local standards
and regulations should be always followed in the final design.
Example 1: OPTBJ board without reset for Safe Torque Off (STO)
The figure above shows a connection example of OPTBJ board for Safe Torque Off safety function
without reset. The switch S1 is connected with 4 wires to the OPTBJ board as shown above.
When the switch S1 is activated (contacts open), the drive goes to STO state and motor (if running)
will stop by coasting. If STO fault action is parameterized as "Alarm", the drive indicates: "30 Safe
torque off". Regardless of the parameterization, activation of STO function causes a coasting stop
for motor.
To allow the returning of the drive to ready state without a reset after S1 is deactivated (contacts
closed), STO Fault action must be parameterized as "Alarm". See application manual for related parameters.
To start the motor operation again, the following sequence is performed.
NOTE! According to EN 60204-1 (Safety of machinery - Electrical equipment of machines), the resetting 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
• 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.
start.
6
Local contacts: https://www.danfoss.com/en/contact-us/contacts-list/
Commissioning vacon • 33
F1
12345
6
L1 L2
MAIN CIRCUIT
L3
PE
PE
L1 L2 L3
U
V W
PE
2
7
PE
PE
PE
W1
M1
M
3
~
U1
1
V1 W1
2
PE
R1
SPEED REFERENCE
S
CCW
CW
W12
1sh 1r 2sh 2p 2s
Basic I/O
1
+10Vref
1
2
AI1+
2
3
AI1
3
OPTBJ
SLOT E
1
STO1+
2
STO1
S1
11
12
W10
1r 2r1b 2b
S6
START
13
14
4
AI2+
4
5
AI2
5
6
24Vout
6
7
GND
7
3
STO2+
4
STO2
21
22
S7
STOP
11
12
S8
RESET
13
14
8
DI1
8
9
DI2
9
10
DI3
10
11
CM
11
25
RO1 C
26
RO1 NO
28
TI1+
12
24Vout
12
13
GND
13
14
DI4
14
15
DI5
15
X23
OFF
29
TI1
16
DI6
16
17
CM
17
18
AO1+
18
19
AO/GND
19
30
+24Vin
20
PE
+24V
0V
Safe torque off
A
RS485BRS485
21 22
Short circuit and earth
fault protected supply
X10
Installed
3045B_UK
AO1
RS485
U
U
U
ON OFF
I
I
I
AI2
AI1
ON
OFF DGND
Example 2: OPTBJ board with reset for Safe Torque Off or EN 60204-1 stop category 0.
The figure above presents a connection example of OPTBJ board for STO safety function with reset.
The switch S1 is connected with 4 wires to the OPTBJ board as shown above. The digital input 3
(DIN3), for example, is wired for the fault reset function. The reset function (not part of any safety
function) can be programmed to any of the available digital inputs.
To prevent starting the motor without reset, STO fault action has to be parameterized as "Fault".
See application manual for related parameters.
When the switch S1 is activated (contacts open), the drive goes to STO state and motor (if running)
stops by coasting. The drive indicates: "30 SafeTorqueOff".
To start the motor operation again, the following sequence is performed.
• Release the switch S1 (contacts closed). The hardware is now enabled but the drive continues to display the fault "30 SafeTorqueOff".
• Acknowledge the releasing of switch by edge sensitive 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 resetting 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 category 0, use the emergency stop button.
Local contacts: https://www.danfoss.com/en/contact-us/contacts-list/
6
vacon • 34 Commissioning
F1
12345
6
L1 L2
MAIN CIRCUIT
L3
PE
PE
L1 L2 L3
U V W
PE
2
7
PE
PE
PE
W1
M1
M
3
~
U1
1
V1
W1
2
PE
R1
SPEED REFERENCE
S
CCW
CW
W12
1sh 1r 2sh 2p 2s
Basic I/O
1
+10Vref
1
2
AI1+
2
3
AI1
3
OPTBJ
SLOT E
1
STO1+
2
STO1
S6
START
13
14
4
AI2+
4
5
AI2
5
6
24Vout
6
7
GND
7
3
STO2+
4
STO2
S7
STOP
11
12
8
DI1
8
9
DI2
9
10
DI3
10
11
CM
11
25
RO1 C
26
RO1 NO
28
TI1+
12
24Vout
12
13
GND
13
14
DI4
14
15
DI5
15
X23
29
TI1
16
DI6
16
17
CM
17
18
AO1+
18
19
AO/GND
19
30
+24Vin
20
PE
OFF
A
RS485BRS485
21 22
X10
Installed
PE
Short circuit and earth
fault protected supply
0V
PE
PE
A10
W3
1r 2r
57
58
+24V
67
68
PE
13142324333441
42
24VDC
A1
A2
0VDC
+
S10
S1
11
12
S11 S12 S21
21
22
PHOENIX CONTACT
S22 S33
PSRSCP24DC/ESD/5X1/1X2/300
RESET
S34 S35
Bridge between S33/S35 for automatic reset.
(Not allowed with emergency stop)
RS1RS2
RS1
RS2
RAMP STOP
3046A_UK
AO1
RS485
U
U
U
ON OFF
I
I
I
AI2
AI1
ON OFF
DGND
Example 3: OPTBJ board with SS1 and safety reset or EN 60204-1 stop category 1.
The figure above presents a connection example of OPTBJ board for SS1 safety function with external safety relay module and with safety reset.
The external safety relay module is connected to the switch S1. The used power supply to switch S1
is 230 VAC as an example. The safety relay module is connected to OPTBJ board with 4 wires as
shown in Figure above.
To configure the drive to perform the fast deceleration with a ramp, it is recommended to use Quick
Stop -function that is activated by digital input, for example DI6 as in Example 3 above. See the application manual for correct parametrization of Quick Stop -function.
until the delay of the safety relay has passed. After safety relay time delay, the drive goes to STO
state. If the motor is still running, it stops by coasting. If STO fault action is parameterized as
"Alarm", the drive indicates: "30 Safe torque off". Regardless of the parameterization, activation of
STO function causes a coasting stop for motor.
To allow the returning of the drive to ready state after S1 is deactivated (contacts closed) and safety
relay is resetted, STO Fault action needs to be parameterized as "Alarm". If STO Fault action is parameterized as "Fault", also the drive needs to be reset to allow ready state. See application manual
for related parameters.
When the switch S1 is activated (contacts open), the drive starts ramping down the output frequency
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
• Acknowledge the releasing of switch by resetting the safety relay. The drive returns to the ready state.
• Giving a valid start command starts running the motor
state. An alarm indication for STO actiavation is displayed if STO Fault action is parameterized as
"Alarm".
6
Local contacts: https://www.danfoss.com/en/contact-us/contacts-list/
Commissioning vacon • 35
More information on the safety relay module may be found in the safety relay documentation.
NOTE! According to EN 60204-1 (Safety of machinery - Electrical equipment of machines), the resetting 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 category1, use emergency stop button.
Local contacts: https://www.danfoss.com/en/contact-us/contacts-list/
6
vacon • 36 Commissioning
6.3 Parameterization of STO functionality
STO functionality is based on hardware, and cannot be bypassed by parameterization. Activating either or both of STO input channels by applying logical '0' causes a coasting stop for the motor and
prevents the restart. The additional actions such as generating fault or alarm from STO activation
or driving the STO state to an output can be parameterized. See application manual for 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)
P3.9.29
(HVAC)
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: Activating STO causes
motor to stop by coasting and 'Not
ready' state. Alarm is displayed,
but drive returns to 'Ready' state
as soon as STO is deactivated.
• Fault, Coast: Activating STO
causes motor to stop by coasting
and 'Fault' state. STO needs to be
deactivated and fault reset before
drive returns to 'Ready' state.
6
Local contacts: https://www.danfoss.com/en/contact-us/contacts-list/
Commissioning vacon • 37
6.4 Checklist for commissioning the OPTBJ board
Nr Step Yes No
Has a risk assessment of the system been carried out to ensure that using the OPTBJ board Safe Torque Off (STO) or Safe Stop 1 (SS1) safety
1
function is safe and according to the local regulations ?
Does the assessment include an examination of whether using external
2
devices such as a mechanical brake is required ?
Has the switch S1 been chosen according to the required safety perfor-
3
mance target (SIL or PL) set during the risk evaluation?
Is the switch S1 required to be lockable or otherwise secured in the OFF
4
position?
Is it ensured that color coding and marking of the switch S1 is in accor-
5
dance with the intended use?
Is the external power of the switch S1 protected (according to EN 60204-
6
1) against supply earth fault and short circuit?
The shaft of a permanent magnet motor might in an IGBT fault situation
rotate up to 180 degrees around the pole of the motor. Has it been en-
7
sured that the system is designed in such a way that the this can be accepted?
Has the STO jumper configuration been done according to the instruc-
8
tions in this manual?
Has the STO input wiring been done according to examples?
9
10
11
12
13
14
15
16
17
18
19
20
Have process requirements (including deceleration time) been considered for correct execution of Safe Stop 1 (SS1) safety function and are
the corresponding settings done?
Is there a risk of conductive contamination (e.g. conductive dust) in the
environment?
If pollution degree 2 cannot be guaranteed, IP54 protection class must
be used.
Have the User's Manual instructions for the specific product been followed?
Does the system need a safety certified prevention of unexpected startup? The safety function has to be provided by an external safety relay.
Has the system been designed in such a way that activating (enabling)
the drive through STO inputs will not lead to an unexpected start of the
drive?
Have only approved units and parts been used?
Is the VACON® 100 family control board 70CVB01582 (141X4153)? (See
the sticker on the VACON® 100 family control board, or “Drive Info” in
VACON® Live)
Is the VACON® 100 system software version FW0072V002, or newer?
(Check the system software version on the keypad or in VACON® Live)
Has a routine been set up to ensure that the functionality of the safety
functions is being checked at regular intervals?
Has this manual been read, understood and followed carefully?
21
Local contacts: https://www.danfoss.com/en/contact-us/contacts-list/
Have the STO and SS1 safety functions been tested properly according
to Chapter 6.5?
6
vacon • 38 Commissioning
6.5 Testing the Safe Torque Off (STO) or Safe Stop 1 (SS1) safety functions
NOTE! Before testing the STO or SS1 safety functions, make sure that the checklist (Chapter 6.2) is
inspected and completed.
NOTE! After connecting the board ALWAYS make sure that the STO or SS1 safety functions are
working properly by testing them before operating the system.
NOTE! Concerning the SS1 safety function, make sure by testing that the drive's stop by ramp function 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 periodically at least once a year.
When the STO safety function is activated, a code: Fault 30 "SafeTorqueOff " appears on the control
keypad display. This indicates that the STO safety function is active. After STO has been deactivated,
the fault remains active until the fault is acknowledged.
6
Local contacts: https://www.danfoss.com/en/contact-us/contacts-list/
Maintenance vacon • 39
13006.emf
13006.emf
7. M
AINTENANCE
CAUTION! If any service or repair is to be conducted on the drive installed with
OPTBJ board please follow the check list given in Chapter 6.2.
CAUTION! During maintenance breaks, or in case of service/repair, the OPTBJ
board 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 functional by testing them. See Chapter 6.5.
7.1 Faults related to the Safe Torque Off (STO) or Safe Stop 1 (SS1) safety functions
The table below shows the normal fault, generated when STO safety function is active:
Fault code Fault ID Explanation Correcting measures
30 SafeTorqueOff 530
STO activated through the
OPTBJ option board
STO function activated. Drive is
in safe state
The table below shows faults that may be generated from the software part that monitors the hardware related to the STO safety function. If some of the faults listed below occur, DO NOT reset the
fault:
Fault code Fault ID Explanation Correcting measures
• Remove the STO jumper from
the control board. See ch. 3.1
and 3.1.1
• Only one OPTBJ board is supported by the drive. Remove
other OPTBJ boards from the
drive, except from slot E.
• OPTBJ option board can only be
installed to slot E. Install the
board to slot E.
• Install the STO jumper to the
control board, when the OPTBJ
board has been removed from
the drive. See ch. 3.1 and 3.1.1
• Check the installation of the
STO jumper on the control
board. See ch. 3.1 and 3.1.1.
• Check the installation of STO
jumper switch on the OPTBJ
board. See ch. 3.1 and 3.1.1
• Check the installation of the
OPTBJ board.
• Restart the drive.
• Change the OPTBJ board if necessary.
• Should the fault re-occur, contact the distributor near to you.
30 Safety configuration 500
30 Safety configuration 501
30 Safety configuration 502
30 Safety configuration 503
30 Safety configuration 504
30 Safety configuration 505
30 Safety configuration 506
STO jumper is installed on the
control board.
More than one OPTBJ option
board detected in the drive.
OPTBJ option board installed to
a wrong slot.
STO jumper missing from the
control board.
Problem detected in STO
jumper installation on the con-
trol board.
Problem detected in STO
jumper installation on the
OPTBJ board.
Communication has been failed
between the control board and
OPTBJ option board.
Local contacts: https://www.danfoss.com/en/contact-us/contacts-list/
7
vacon • 40 Maintenance
Fault code Fault ID Explanation Correcting measures
30 Safety configuration 507
30 Safety diagnostics 520
30 Safety diagnostics 521
30 Safety diagnostics 522 Atex-thermistor short-circuit.
30 Safety diagnostics 523
30 Safety diagnostics 524
30 Safety diagnostics 525
30 Safety diagnostics 526
30 Safety diagnostics 527
The hardware does not support
the OPTBJ board.
There is a diagnostic failure in
the STO safety function. This
fault occurs when the STO
inputs are in a different state for
more than 500 ms.
Atex-thermistor diagnostic
fault.
Problem occured in internal
safety circuit
Overvoltage detected in safety
option board
Undervoltage detected in safety
option board
Internal failure detected in
safety option board CPU or
memory handling
Internal failure detected in
safety function
• Restart the drive.
• Should the fault re-occur, contact the distributor near to you.
• Restart the drive.
• If the restart does not help,
check the wiring: Both STO
input channels of OPTBJ need
to be on the same state, i.e.
safety device controlling the
inputs needs to feed or cut
power from both STO1 and STO2
channels simultaneously.
• If the inputs are on the same
state and the fault re-occurs,
replace the OPTBJ board.
• Should the fault re-occur, contact the distributor near to you.
Deliver the fault report to the
distributor, see fault details for
more information.
• Restart the drive.
• If the restart does not help,
change the OPTBJ board.
• Should the fault re-occur, contact the distributor near to you
• 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, contact the distributor near to you
• Reset the drive and restart. If
the fault reoccurs contact your
nearest distributor.
• Reset the drive and restart. If
the fault reoccurs contact your
nearest distributor.
• Reset the drive and restart. If
the fault reoccurs contact your
nearest distributor.
• Reset the drive and restart. If
the fault reoccurs contact your
nearest distributor.
• Reset the drive and restart. If
the fault reoccurs contact your
nearest distributor.
7
Local contacts: https://www.danfoss.com/en/contact-us/contacts-list/
Thermistor function (ATEX) vacon • 41
13006.emf
13006.emf
13006.emf
8. T
HERMISTOR FUNCTION
(ATEX)
The thermistor overtemperature supervision is designed in accordance with ATEX directive 94/9/
EC. It is approved by VTT Finland for group II (certificate nr. VTT 06 ATEX 048X), category (2) in the
'G' area (area in which potentially explosive gas, vapor, mist or air mixtures are present) and 'D'
area (area with combustible dust). The "X" in the certificate number refers to special conditions for
safe use. See the conditions in the last note in this page.
0537 II (2) GD
It can be used as an overtemperature tripping device for motors in explosive area (EX motors).
NOTE! The OPTBJ board also contains the Safe Torque Off (STO) safety function. When STO is not
intended to be used, inputs STO1+(OPTBJ:1), STO2+(OPTBJ:3) are to be connected to +24V (for example, pin 6 in VACON® 100 family control board). STO1-(OPTBJ:2). STO2- (OPTBJ:4) are to be connected to GND (for example, pin 7 or 13 on VACON® 100 family control board).
NOTE! Safety devices like the OPTBJ board must be correctly incorporated into the entire system.
The functionality of the OPTBJ board is not necessarily suitable for all systems. The entire system
must be designed in compliance with all relevant standards within the field of industry.
CAUTION! The information in this manual provides guidance on the use of thermistor function for protecting overheating of motors in explosive atmosphere. However, the end product/system designer is responsible for ensuring that the
system is safe and in compliance with relevant regulations.
CAUTION! During maintenance breaks, or in case of service/repair the OPTBJ
board might have to be removed from its slot. After reconnecting the board
ALWAYS make sure that the thermistor function is working correctly by testing it.
CAUTION! The thermistor function on OPTBJ board with VACON® 100 family con-
trol is used to protect the overheating of motors in explosive atmosphere. The
drive itself including OPTBJ board can not be installed in explosive atmosphere.
NOTE!
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- and ExnA- motors, the PTC sensors must be certified together with the motor according to the requirements of the type of protection. The allowed ambient temperature range for the drive is -10ºC…+50ºC.
The special conditions required for safe use (X in the certificate number): This function can be used
Local contacts: https://www.danfoss.com/en/contact-us/contacts-list/
8
vacon • 42 Thermistor function (ATEX)
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: DPD01855 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
Marking of the equipment
has been designed in conformity 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: Validation
- EN 60079-14 (2007)
Electrical apparatus for explosive gas atmospheres.
Part 14: Electrical installations in hazardous area (other than mines).
- EN 61508-3(2010)
Functional safety of electrical/electronic/programmable electronic safety- related systems – Part3:
Software requirements
- EN ISO/IEC 80079-34 (2011)
Explosive atmospheres – Part 34: Application of quality systems for equipment manufacture.
- EN 50495 (2010)
Safety devices for ignition prevention.
VTT Industrial Systems, Electrical Ex apparatus, the Notified Body having identification number 0537, has
assessed the conformity of thermal motor protection system and has issued the certificate VTT 06 ATEX 048X.
It is ensured through internal measures and quality control that the product conforms at all times to the
requirements of the current Directive and the relevant standards.
8
Local contacts: https://www.danfoss.com/en/contact-us/contacts-list/
Thermistor function (ATEX) vacon • 43
STO1
+
STO2
-
RO
=
3~
VACON 100 CONTROL UNIT
Control board
OPTBJ board, slot E
POWER UNIT
Thermistor
Atex S afety
Functi on
Atex S afety
Functi on
Hardware
STO 1
Hardware
STO 2
11575B_uk
Figure 15. Thermistor function principle in VACON® 100 family AC drive with the OPTBJ board,
MR4-10
Local contacts: https://www.danfoss.com/en/contact-us/contacts-list/
8
vacon • 44 Thermistor function (ATEX)
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
Figure 16.STO principle with OPTBJ board and VACON® 100 family control board MR12
8
Local contacts: https://www.danfoss.com/en/contact-us/contacts-list/
Thermistor function (ATEX) vacon • 45
OPTBJ:
OPTBJ:
OPTBJ
11580_uk
8.1 Technical data
8.1.1 Functional description
The thermistor supervision circuit of the OPTBJ board is designed to provide a reliable way of disabling the drive modulation in case there is an overtemperature at the motor thermistor(s).
By disabling the drive modulation, the feeding of the energy to the motor is prevented and a further
heating up of the motor due to this is avoided.
The thermistor supervision circuit meets the requirements in the ATEX directive by directly activating the "STO" safety function of the VACON® 100 family (See Figure 15) and thus provides a reliable,
software and parameter independent way of preventing the energy supply to the motor.
8.1.2 Hardware and connections
See Chapter 5.3.5.
The thermistor (PTC) is connected between the terminals 28(TI1+) and 29(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-protection sensor as specified in DIN 44081/DIN
440
8.1.3 Atex function
When drive is connected to the main power and if the motor temperature is below overtemperature
limits (see Figure 17), the drive goes to ready state. The motor may start after a valid start command.
If the motor temperature is above the overtemperature limits (see Figure 17), fault 29 (Atex thermistor) is activated.
When the resistance of the thermistor(s) mounted in the motor goes above 4 kOhm due to motor
overheating, the drive modulation is disabled within 20ms.
According to Figure 17, when the temperature falls below 2 kOhm, the thermistor function allows
fault reset and entering to ready state.
Local contacts: https://www.danfoss.com/en/contact-us/contacts-list/
8
vacon • 46 Thermistor function (ATEX)
8.1.4 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, Fault 30, Safety diagnostic (subcode 522) is generated.
When the short circuit has been removed, the drive can be reset only after restarting the drive.
The short circuit monitoring can be enabled or disabled using the jumper X23 in ON or OFF position
respectively. The jumper is set in ON position by factory default.
8.2 Commissioning
NOTE! Installation, testing and service work on the OPTBJ board can be performed only by qualified
persons.
NOTE! It is not allowed to perform any repair work on the OPTBJ board. Return faulty boards to the
manufacturer for analysis.
NOTE! It is recommended to test the ATEX functionality using thermistor input on OPTBJ board periodically (typically once a year). For testing, activate the thermistor functionality (e.g. remove Atexthermistor plug from the OPTBJ board). The drive enters to fault state and indicates fault 29 (Atexthermistor 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 belonging the motor supply cables or any other main circuit cables. A shielded control cable
must be used. See also Chapter
3.
Maximum cable length without
short circuit monitoring. Shield
must be connected to the drive's lid
(PE).
Maximum cable length with short circuit monitoring.
X23 : ON
X23 : OFF
>= 1.5 sq mm 1500 meters 250 meters
8.2.2 Fault diagnosis of thermistor function
The table below shows the normal fault / warning, generated when thermistor input is active
Fault code Fault ID Explanation Correcting measures
The resistance of thermistor
input must go below 2 kΩ to be
able to restart the drive.
29 Atex-thermistor 280
Atex-thermistor has detected
overtemperature.
See the fault table in chapter 7.1.
8
Local contacts: https://www.danfoss.com/en/contact-us/contacts-list/
www.danfoss.com
Vacon Ltd
Member of the Danfoss Group
Runsorintie 7
65380 Vaasa
Finland
Document ID:
DPD00470G
Rev. G
Sales code: DOC-OPTBJ+DLUK
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