Danfoss VACON and VLT FC Application guide

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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

Contents

1 Introduction

1.1 Purpose

1.2 Scope

1.3 Abbreviations

2 Safety Functions SLS and SSR

3 SLS and SSR Implementation

3.1 Circuit Diagram

3.2 Safety Function Operation and Timing

3.2.1 Initial Conditions 11

3.2.2 Fault Handling 11

3.2.3 SLS Operation 11

3.2.4 SSR operation 11

3.3 Parameters and Conguration

4 Ordering Data for DOLD Components

4.1 Frequency Monitor

5 Functional Safety-related Data

5.1 SIL Calculation

Index

Introduction Encoder-less Safety Functions SLS, SSR using DOLD Frequency Monitor

1 Introduction

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:

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

•

Scope

1.2

This manual is intended for application designers, for realizing safe speed functions of frequency converters without encoder feedback, using an external frequency monitor.

Abbreviations

1.3

PL Performance Level

SIL Safety Integrity Level

SLS Safely Limited Speed

SSR Safe Speed Range

STO Safe Torque O

Table 1.1 List of Abbreviations

SLS limit

Speed

Time

130BF781.10

SSR upper limit

SSR lower limit

Speed

Time

130BF782.10

Safety Functions SLS and SS... Functional Safety Application Guide

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.

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.

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.

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 o the power to the motor.

2 2

Illustration 2.2 SSR Function

SLS and SSR Implementation Encoder-less Safety Functions SLS, SSR using DOLD Frequency Monitor

3 SLS and SSR Implementation

The SLS safety function implementation is based on the STO function and the following safety-related components:

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

•

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).

lter for measuring relays (3

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.

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.

Chapter 3.2 Safety Function Operation and Timing includes the SLS operation and timing.

Remove the jumper wire between control terminals 12, 37, 38 in the frequency converter.

-SF8

RESET

+FIELD

Ensure that the STO cables are shielded if they are longer than 20 m (65.6 ft) or outside the cabinet.

-TA1

VLT FC 280 Frequency

converter

PE/GND

GND

PE/GND

L1 L2 L3

-FC1 _

95(PE)

91(L1)

92(L2)

93(L3)98(W)

97(V)

96(U)

99(PE)

-U2

NSGAFÖU 1.8/3 kV BK min. 2.5 mm

(14 AWG)

-WD1

-MA1

M 3~

BN BK GY

U1 V1 W1

E1a E2L E2H E1b E3L E3H

14 23 24 A1+ A2 RES T1 T2 RF

4838

UH6937

-FC31

24 V DC 0 V DC

2 4 6

3 5

130BF784.10

SLS and SSR Implementation Functional Safety Application Guide

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.

3 3

Illustration 3.1 FC 280 and UH 6937 Wiring Diagram

SD2-

+FIELD

L1 L2 L3

12345

-FC1

PE/GND

-TA1 NX Series Frequency Converter

L1 L2 L3

U V WPE/GND

PE/GND

-MA1

-WD1

PE/GND

U1BNW1V1

E1a

E2L

E2H E1b E3L E3H

GND

14 24

13 23 A1+ A2 RES T1 T2 RF

38 48

PE/GND

-WGB1

PE/GND

1 432

SD1-

SD1+

RO1 NO

RO1 C

RO1 NC

SD2+

RO2 C26RO2 NO

TI1-

TI1+

-AG2 OPTAF IFS+2XRO+PTC SLOT B

X10

X12

UNCUT

Thermistor short circuit supervision

-FC31

-FC32

-FC33 13

-SF8 RESET

24 V DC 0 V DC

UH6937

+FIELD

130BF789.10

NSGAFÖU 1.8/3 kV BK min. 2.5 mm

(14 AWG)

SLS and SSR Implementation Encoder-less Safety Functions SLS, SSR using DOLD Frequency Monitor

Illustration 3.2 NX Drive, OPT-AF, and UH 6937 Wiring Diagram

RES

Use short-circuit protected cable (if not inside an IP54 installation cabinet)

Remove the jumper wire between control terminals 37 and 12 or 13 in the frequency converter.

UH6937

12345

-FC1

91(L1)

92(L2)

93(L3)

96(U)

97(V)

98(W)

99(PE)

-TA1 VLT FC 302 frequency converter

PE/GND

-MA1 3~

PE/GND

-WD1

-U2

E1a

E2L

E2H E1b E3L E3H

23 A1+ A2

-FC 31

-SF8 RESET

T2 RF

38 48

GND

PE/GND

+FIELD

PE/GND

95(PE)

PE/GND

14 24

12 or 13

L1 L2 L3 24 V DC 0 V DC

GYBK

V1 W1

130BF790 .10

NSGAFÖU 1.8/3 kV BK min. 2.5 mm

² (14 AWG)

SLS and SSR Implementation Functional Safety Application Guide

3 3

Illustration 3.3 FC 302 and UH 6937 Wiring Diagram

+FIELD

L1 L2 L3

12345

-FC1

PE/GND

-TA1 VACON 100 frequency converter

L1 L2 L3

U V WPE/GND

PE/GND

-MA1

-WD1

PE/GND

U1BNW1V1

BK GY

E1a

E2L

E2H E1b E3L E3H

GND

14 24

13 23 A1+ A2 RES T1 T2 RF

38 48

PE/GND

-WGB1

PE/GND

1 432

-FC31

-FC32

-FC33 13

-SF8 RESET

24 V DC 0 V DC

UH6937

+FIELD

Supervision ON (default)

Short circuit supervision

Supervision OFF

X23

STO board not activated

STO board activation

X10

STO board activated (default)

-AB1 SLOT C, D, E OPT-BJ

Contact

RO1

Thermistor Input

TI1

STO1+2STO1-3STO2+4STO2-

25CO26

TI1-

TI1+

130BF791.10

NSGAFÖU 1.8/3 kV BK min. 2.5mm

(14 AWG)

SLS and SSR Implementation Encoder-less Safety Functions SLS, SSR using DOLD Frequency Monitor

Illustration 3.4 VACON® 100, OPT-BJ, and UH 6937 Wiring Diagram

PE L1 L2 L3

Motor Protection

L1’

L2’

L1’

L3’

E1a

E2H

E1b

E3H

UH6937

LG5130

130BF783.10

SLS and SSR Implementation Functional Safety Application Guide

Illustration 3.5 shows the LG 5130 Circuit Diagram with noise ltering between the 3 phases of the frequency converter and the frequency monitor UH 6937.

3 3

Illustration 3.5 LG 5130 Circuit Diagram

A2 GND

E2H E2aE2L

E3H E3L E1b

A2 GND

E2H

E2aE2L

E3H

E3L E1b

14 23

T1RFRES

38GND

24 14

T1 RFRES

GND

A1+A

SW1 SW2 SW3 SW4

M10823_d M10823_d

UH6937 UH6937/__1

130BF788.10

SLS and SSR Implementation Encoder-less Safety Functions SLS, SSR using DOLD Frequency Monitor

Terminal designation Signal designation

A1+ 24 V DC

A2 0 V

E1a, E1b, E2L, E2H, E3L, E3H Frequency measuring inputs

GND Reference potential for semiconductor monitoring output and control outputs

13, 14, 23, 24 Forcibly guided NO contacts for release circuit

38, 48 Semiconductor-monitoring output

T1, T2 Control output

RES, RF, SW1, SW2, SW3, SW4 Control input

A+, A GND Analog output

Illustration 3.6 Terminals Description

SLS and SSR Implementation Functional Safety Application Guide

3.2 Safety Function Operation and Timing

The safe speed monitoring has to be congured for the speed limits in the frequency converters applications. The customer is responsible for dening the speed limits on the risk assessment. The commissioning test report is made available for the nal assessment and for future references.

3.2.1 Initial Conditions

If the safe speed limit monitor is congured without the start-up delay and the RF feedback circuit is closed, it is active immediately after the power-on.

3.2.2 Fault Handling

When faults are detected on or in the device, they are indicated with a message in the display. If the fault requires a reset of the device, the alarm and the associated diagnostic message has to be acknowledged rst. Press the left key for approximately 3 s to initiate a reset of the device.

NOTICE

If a system failure is detected again after restart, the device must be replaced and sent back to the manufacturer.

3.2.3 SLS Operation

Typically, the SLS safety function is used for safe speed monitoring according to a dened speed limit. In this case, the SLS function denes the speed limit where it is considered safe for personal interaction with the machine. As long as the frequency of the frequency converter is within the dened limit, the STO function is not active. When the output frequency goes beyond the limit value, STO is immediately activated so the motor coasts and comes to a standstill. This coasting time must be considered before allowing the access to the dangerous zone.

The safe output on the frequency monitor UH 6937 is active and the output relays remain closed, as long as the actual speed is lower than the safe speed limit parameter (SLS limit).

If the actual speed exceeds the safe speed limit parameter (SLS limit), speed output relays are opened, and the safe output signal is removed.

If an internal fault occurs, the SLS safety function can be congured for automatic reset. If the function is congured for a manual reset, the RESET input should be provided for normal operation after removing the limit violations.

The module UH 6937 always monitors the congured frequency limits. The frequency module does not have its own safe inputs, therefore a third-party functional safety system, for example a fail-safe PLC system, is used. It activates the safe function when a safe function is demanded. This means that more safety logic can be prepared based on the status of the frequency module relays in the PLC. For example, the PLC logic controls the access to the dangerous zone via its output signal (door control). The SLS output (relays) is connected to the failsafe PLC’s safety input. The access is allowed as long as the frequency is below the SLS limit. If the speed limit is exceeded, the STO of the frequency converter is immediately activated via the fail-safe PLC output to bring the system to a safe state.

The input frequency is compared to the setting value. As the device measures the cycle duration, the fastest frequency measurement is possible. Should the overfrequency function be set, the output relay switches to the alarm mode when the set response parameter value exceeds the Should the frequency decrease to a value below the response parameter, minus the set hysteresis, the output relay is activated after the expiry of the reset delay time period(tF). It then returns to its preset allowed supervisory state. The underfrequency function means that the output relay switches to the alarm mode when the set response parameter value drops below the set alarm-delay function(tV) time period. When the frequency returns to the range governed by the response parameter, plus the set hysteresis, the output relay returns to the preset allowed state after the expiry of the reset-delay time period(tF).

dened value in the alarm-delay function (tV ).

3.2.4 SSR operation

The SSR function is used for speed monitoring within or outside of a dened speed range.

In the internal window function mode, the output relay switches to the alarm setting when the frequency exceeds the preset allowed range of both the upper and lower response parameters, minus and/or plus the preset hysteresis values (upper response parameter minus and/or the lower response parameter plus the relative hysteresis values). The output relay again switches back to the preset allowed range after the expiry of the reset-delay time period (tF).

In the external window function mode, the monitoring function acts inversely to the internal window function.

Should the manual reset function be activated, the output relay remains in alarm mode when the frequency returns to the preset allowed range. A reset of the saved

3 3

Threshold

Hysteresis

Overfrequency

Underfrequency

Alarm memory

Monitoring function

“Overfrequency”

Monitoring function

“Underfrequency”

Monitoring function

“Inside range”

(A1/A2)

}

Threshold

Hysteresis

}

130BF785.10

V F

t = Start-up delay, t = Alarm delay, t = Response delay

M11332

Output relay

K1/K2

SLS and SSR Implementation Encoder-less Safety Functions SLS, SSR using DOLD Frequency Monitor

parameter is possible when the reset input is activated or the auxiliary voltage is shut down.

When a start-up delay time period (tA) is set, the set startup delay time period expires initially when the auxiliary

voltage of the equipment is switched on and the “RF” feedback circuit is closed. The start-up delay time period also expires after a reset of the manual reset mode. During this time period, a frequency evaluation is disabled and

the output relays remain at the preset allowed setting. The start-up delay function can, for example, override an alarm message during the start-up stage of a generator or electric motor. Should the feedback circuit not be closed after a reset (in the manual reset mode), the equipment goes into a safe error state.

The frequency monitoring operation is shown in Illustration 3.7.

Illustration 3.7 Frequency Monitor Timing

13 +23

ON K1/K2 ERR

UH6937

safemaster

DOLO

actual frequency 100Hz

130BF786.10

SLS and SSR Implementation Functional Safety Application Guide

3.3 Parameters and Conguration

The equipment can be congured via the display and the setting keys on the display. See Illustration 3.8.

To enter the parameterization-mode on the device, follow these steps:

1. Press and hold the [OK] key.

2. Press the [Reset] key.

3. A display test follows and has to be acknowledged using the [OK] key, when it was successful.

4. It is now possible to change the parameterization. Before the device adopts changed parameters, they must be reasons.

conrmed once more for safety

Follow the installation guide from the manufacturer for a detailed description. Table 3.1 shows a default congu- ration of the frequency monitor.

The safe speed limit parameter (SLS limit) is congured to the upper limit parameter of frequency mode 1. The lower limit is congured to 0.0 Hz.

3 3

1 OK

4 Reset

Illustration 3.8 Frequency Monitor Device Display

▲ ▼

SLS and SSR Implementation Encoder-less Safety Functions SLS, SSR using DOLD Frequency Monitor

1. Parameterization

1.1 Monitoring function

Overfrequency X

Underfrequency –

Inside range –

2. Display settings

1.2 Limits

1.3 Hysteresis

1.4 Time Delay

1.5 Alarm memory

1.6 Muting function

2.1 Languages

2.2 Contrast

2.3 Backlight

2.4 Status indicator

Outside range –

Frequency mode 1

Upper limit 400.0 Hz

Lower limit 200.0 Hz

Frequency mode 2

Upper limit 400.0 Hz

Lower limit 200.0 Hz

Frequency mode 3

Upper limit 400.0 Hz

Lower limit 200.0 Hz

Frequency mode 4

Upper limit 400.0 Hz

Lower limit 200.0 Hz

Start-up delay 0.0 s

Response Delay 0.0 s

Alarm delay 0.1 s

Changeover bridging 0.0 s

Alarm memory X

Automatic reset –

Activate –

Deactivate X

English X

Deutsch –

Francais –

50 %

OFF –

10 s X

1 min –

5 min –

Manual X

10 s –

1 min –

5 min –

SLS and SSR Implementation Functional Safety Application Guide

3. Factory settings

Parameters

Display settings

Parameter + display settings

4. Change tracking

Activate

5. About UH 6937

Table 3.1 Frequency Monitor Conguration

3 3

UH 6937 .02

/ 0 DC 24 V

_ _ _

Nominal voltage

0 = Standard 1 = with dierent frequency mode and analogue output

Max. response value 0 = 600 Hz 1 = 1000 Hz

Type o terminals PS (plug-in screw)

pluggable terminal blocks, with screw terminals

Contacts

Type

130BF787.10

Ordering Data for DOLD Comp... Encoder-less Safety Functions SLS, SSR using DOLD Frequency Monitor

4 Ordering Data for DOLD Components

4.1 Frequency Monitor

The ordering information for the DOLD frequency monitor is shown in Illustration 4.1.

Description Type Order

number

Safe frequency

monitor

Noise suppression

lter

Illustration 4.1 Ordering Example

UH6937.02PS

DC24V

LG5130 0065015 2

0066820 1

Pcs. /

Pkt.

1) Even though the UH6937 has enough EMC immunity for normal conditions, the suppression lter for each channel of measurement is needed only when the frequency monitor module does not function correctly due to high EMC or high frequency noise.

Functional Safety-related D... Functional Safety Application Guide

5 Functional Safety-related Data

5.1 SIL Calculation

The SLS safety function consists of 3 subsystems:

Frequency converter

•

Frequency monitor

•

Functional safety system, such as fail-safe PLC

•

These have dierent safety-related data.

The values for the fail-safe PLC must be at least the shown values in Table 5.3.

IEC 61508 SIL2

EN 62061 SILCL 2

EN/ISO 13849: 2006 PL d Category 3

EN 61800-5-2 SIL2

PFH

1x10

-10

5 5

Table 5.1 Subsystem VLT® AutomationDrive FC 302

IEC 61508 SIL3

EN 62061 SILCL 3

EN/ISO 13849: 2006 PL e Category 4

PFH

Table 5.2 Subsystem Frequency Monitor

IEC 61508

EN 62061

EN/ISO 13849: 2006

EN 61800-5-2

PFH

Table 5.3 Subsystem Fail-safe PLC

IEC 61508 SIL2

EN 62061 SILCL 2

EN/ISO 13849: 2006 PL d Category 3

EN 61800-5-2 SIL2

PFH

Table 5.4 SLS Safety Function

≥SIL2

≥SILCL 2

≥PL d ≥Category 3

≥SIL2

<9.1x10-8/h

-10

4.43x10

< 1x10-7/h

Index Encoder-less Safety Functions SLS, SSR using DOLD Frequency Monitor

Index

DIN EN/ISO 13849: 2006..................................................................... 17

DOLD LG 5130.......................................................................................... 4

DOLD UH 6937......................................................................................... 4

EN 61800-5-2.......................................................................................... 17

EN 62061.................................................................................................. 17

External window function................................................................. 11

Fail-safe PLC............................................................................................... 4

Fault handling........................................................................................ 11

Frequency monitor conguration.................................................. 13

IEC 61508................................................................................................. 17

Inside range.............................................................................................. 3

Internal window function.................................................................. 11

Outside range........................................................................................... 3

Overfrequency......................................................................................... 3

PFH............................................................................................................. 17

Safe Torque O......................................................................................... 3

SIL calculation........................................................................................ 17

SLS operation......................................................................................... 11

SSR operation......................................................................................... 11

STO............................................................................................................... 3

Danfoss VACON and VLT FC Application guide

Specifications and Main Features

Frequently Asked Questions

User Manual