Danfoss VACON and VLT FC Application guide
ENGINEERING TOMORROW
Functional Safety Application Guide
Encoder-less Safety Functions SLS, SSR using DOLD Frequency Monitor
VACON® and VLT® FC-series
vlt-drives.danfoss.com
Contents |
Functional Safety Application Guide |
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Contents
1 Introduction |
2 |
1.1 Purpose |
2 |
1.2 Scope |
2 |
1.3 Abbreviations |
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2 Safety Functions SLS and SSR |
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3 SLS and SSR Implementation |
4 |
3.1 Circuit Diagram |
5 |
3.2 Safety Function Operation and Timing |
11 |
3.2.1 Initial Conditions |
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3.2.2 Fault Handling |
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3.2.3 SLS Operation |
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3.2.4 SSR operation |
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3.3 Parameters and Con€guration |
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4 Ordering Data for DOLD Components |
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4.1 Frequency Monitor |
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5 Functional Safety-related Data |
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5.1 SIL Calculation |
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Index |
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MN91A102 |
Danfoss A/S © 04/2017 All rights reserved. |
1 |
Introduction Encoder-less Safety Functions SLS, SSR using DOLD Frequency Monitor
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1 |
1 Introduction |
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1.1 Purpose
This manual describes how to implement the safety functions Safely Limited Speed (SLS) or Safe Speed Range (SSR) using DOLD UH 6937 frequency monitor without encoder.
The DOLD module can be used with the following products:
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VLT® HVAC Drive FC 102
VLT® Refrigeration Drive FC 103
VLT® AQUA Drive FC 202
VLT® Midi Drive FC 280
VLT® AutomationDrive FC 301
VLT® AutomationDrive FC 302
VACON® 100 Industrial
VACON® 100 Flow
VACON® NXP Liquid Cooled
VACON® NXP System Drive
VACON® NXP Air Cooled
VACON® NXP Common DC Bus
VACON® NXP Liquid Cooled Enclosed Drive
VACON® NXP Liquid Cooled Common DC Bus
1.2 Scope
This manual is intended for application designers, for realizing safe speed functions of frequency converters without encoder feedback, using an external frequency monitor.
1.3 Abbreviations
PL |
Performance Level |
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SIL |
Safety Integrity Level |
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SLS |
Safely Limited Speed |
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SSR |
Safe Speed Range |
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STO |
Safe Torque O‚ |
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Table 1.1 List of Abbreviations
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Danfoss A/S © 04/2017 All rights reserved. |
MN91A102 |
Safety Functions SLS and SS... |
Functional Safety Application Guide |
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2 Safety Functions SLS and SSR
The Safely Limited Speed (SLS) function monitors the speed to a set limit value without any encoder feedback, see Illustration 2.1. The frequency of the motor is measured and compared to the limit value. If the measured value is more than the set value, then the safety output relay is deactivated to trigger the STO function.
Speed |
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SLS limit |
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Time |
Illustration 2.1 SLS Function
The Safe Speed Range (SSR) function monitors the speed within a given range or outside a given range. See
Illustration 2.2.
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Monitoring within the given range:
If the frequency is within the given speed range, the STO signal is not active. If the measured frequency is outside the given speed range, the relay output triggers the STO function of the frequency converter.
Monitoring outside the given range:
If the frequency is outside the de€ned speed range, the STO signal is not active. If the measured frequency lies inside the limits, the relay output triggers the STO function of the frequency converter.
In the standard module variant 0, 1 of the following monitoring functions is selected:
•Over frequency
•Under frequency
•Inside range
•Outside range
The variant 1 module has extra selection inputs for selecting 4 frequency modes during the operation.
Speed
SSR upper limit SSR lower limit
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NOTICE
If the frequency converter does not have an integrated STO function, the relay outputs can be used to activate the motor contactors to cut off the power to the motor.
Time
Illustration 2.2 SSR Function
MN91A102 |
Danfoss A/S © 04/2017 All rights reserved. |
3 |
SLS and SSR Implementation |
Encoder-less Safety Functions SLS, SSR using DOLD Frequency Monitor |
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3 SLS and SSR Implementation
The SLS safety function implementation is based on the |
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STO function and the following safety-related components: |
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3 3 • |
Frequency monitor (3rd party DOLD UH 6937) |
The UH 6937 frequency module does not have safe inputs to activate and deactivate the safety functions. In variant 0, the module always monitors the frequency. The monitoring can only be muted by selecting the parameter in the display. In variant 1, there are 4 digital safe inputs available to select di‚erent frequency modes, and 1 of the combinations is the muting function.
•Noise suppression filter for measuring relays (3rd party DOLD LG 5130), optional
These €lters are only required if there is measurement errors after complete installation.
•Third-party functional safety system or fail-safe PLC (≤ SIL2), optional
A fail-safe PLC is required to implement the safety logic based on the status of the relay outputs of a frequency module. One of the use cases is, that the relay output status is ignored as long as the safety door is locked for SLS speed. Once the door is opened, the safety relay output is used to activate the STO of the frequency converter for speed limit violations.
The circuit example in chapter 3.1 Circuit Diagram shows the DOLD UH 6937 used with a Danfoss frequency converter FC-series or VACON® series.
The auxiliary voltage 24 V is connected to terminals A1–A2. Any 24 V PELV or SELV supply can be used. If no additional devices are supplied via terminal 12 or 13 (+24 V), A1 can be connected to terminal 12 or 13. A2 can be connected to terminal 20 (0 V).
Terminals E1a, E1b, E2L, E2H, E3L, and E3H form the measuring input. For low voltages (AC 8–280 V), the measuring voltage is connected to E1a–E2L and E1b–E3L. For higher voltages (AC 16–600 V), the measuring voltage is connected to E1a–E2H and E1b–E3H.
When monitoring single-phase AC voltage, the terminals E1a–E2L or E1a–E2H should be connected directly to the frequency converter. The terminals E1b–E3L or E1b–E3H should be connected directly to the motor connection terminals.
NOTICE
Separate wires in separate cables with spacing in between have to be used for each of the frequency inputs. When monitoring 3-phase AC voltages, these terminals have to be wired directly to the motor connection terminals.
WARNING
RISK OF DEATH AND SERIOUS INJURY
If external forces act on the motor, for example in case of vertical axis (suspended loads) the motor must be equipped with extra measures for fall protection. For example, install extra mechanical brakes.
The noise €lter (LG 5130) has 4 inductances connected in series in each path for the 3 phases (input L1/L2/L3). This provides broad band €ltering up to high frequencies. If the PE is connected, a Y-capacitor connected to PE is activated and provides increased €ltering (T-€lter).
The noise €lter is connected via its input terminals L1/L2/L3 to the frequency converter output and the frequency monitor device to the €lter outputs L1’/L2’/L3’.
By connecting the noise €lter between the frequency converter and the measuring frequency monitor device, the current …owing via the coupling capacitances is reduced. The reduction happens because the €lter elements create a rising impedance with a rising frequency. This prevents disturbance or damage on the connected device. Protection as shown in Illustration 3.5.
It is not mandatory to connect the PE to the frequency monitor device terminals, but it increases the €lter e‚ect.
Chapter 3.2 Safety Function Operation and Timing includes the SLS operation and timing.
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Danfoss A/S © 04/2017 All rights reserved. |
MN91A102 |
SLS and SSR Implementation |
Functional Safety Application Guide |
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3.1 Circuit Diagram
Illustration 3.1 shows the UH 6937 Circuit diagram. The relay contacts 13–14 and 23–24 can be used as STO input to the frequency converter.
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PE/GND |
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L1 |
L2 |
L3 |
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24 V DC |
0 V DC |
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-FC1 _F |
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Remove the jumper wire between control |
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terminals 12, 37, 38 in the frequency converter. |
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PE/GND |
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Ensure that the STO cables are shielded if they |
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-TA1 |
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VLT FC 280 |
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Frequency |
12 |
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converter |
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37 |
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1 |
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38 |
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-FC31 |
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2 |
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13 |
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55 |
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-SF8 |
E |
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14 |
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RESET |
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PE/GND |
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U |
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-U2 |
14 |
23 |
24 |
A1+ |
A2 |
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RES |
T1 |
T2 |
RF |
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E1a 13 |
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E2L |
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V |
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E2H |
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UH6937 |
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U |
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E1b |
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E3L |
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W |
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E3HGND |
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PE/GND |
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+FIELD |
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-WD1 |
BN |
BK GY |
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SH |
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U1 |
V1 W1 |
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M |
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-MA1 |
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BK |
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3~ |
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min. 2.5 mm2 (14 AWG) |
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PE/GND |
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PE/GND |
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Illustration 3.1 FC 280 and UH 6937 Wiring Diagram
3 3
MN91A102 |
Danfoss A/S © 04/2017 All rights reserved. |
5 |
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