Danfoss VLT HVAC Drive FC 102, VLT AutomationDrive FC 302, VLT PTC Thermistor Card MCB 112, VLT AQUA Drive FC 202 Operating Instructions Manual

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MAKING MODERN LIVING POSSIBLE

Operating Instructions

VLT® PTC Thermistor Card MCB 112

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

vlt-drives.danfoss.com

Contents

1 Introduction

3

1.1 Purpose of the Manual

3

1.2 Additional Resources

3

1.3 Document and Software Version

3

1.4 Products Covered

3

1.5 Functional Overview

3

1.5.1 Intended Use 3

1.5.2 Foreseeable Misuse 4

1.5.3 Thermal Motor Protection 4

1.5.4 ATEX ETR Thermal Monitoring 4

1.5.5 Tripping Function 4

1.5.6 Safe Separation 4

1.5.7 Safe Disconnection Principle 4

1.6 Motor Requirements

5

1.6.1 Motor Limits and Rules 5

1.6.2 Additional Motor Requirements 5

1.7 Approvals and Certications

5

1.8 Symbols, Abbreviations, and Conventions

6

2 Safety

7

2.1 Safety Symbols

7

2.2 Qualied Personnel

7

2.3 Safety Precautions

7

3 Installation

9

3.1 Safety Instructions

9

3.2 Installation of Sensor Circuit Wires

9

3.3 Installation of the VLT® PTC Thermistor Card MCB 112

10

4 Commissioning

12

4.1 Operation and Maintenance

12

4.1.1 Monitoring Sensor Resistance 12

4.2 Parameter Set-up

13

4.2.1 Alarm Handling 13

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

14

4.3.1 Maximum Current 14

4.3.2 Maximum Current Limit 14

4.3.3 Minimum Motor Frequency 14

4.3.4 Maximum Motor Frequency 15

4.3.5 Minimum Switching Frequency 15

Contents Operating Instructions

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

4.3.6 Disable Protection Mode 15

4.3.7 Safe Torque O Functionality 15

5 Application Examples

17

6 Maintenance and Troubleshooting

19

6.1 Maintenance

19

6.2 Troubleshooting

19

6.2.1 Alarm/Warning Code List 19

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

7 Technical Specications

21

7.1 Mains Supply

21

7.2 Control Inputs and Outputs

21

7.3 Ambient Conditions

21

7.4 Other Specications

22

7.5 Safety Characteristics of the Built-in MCB 112

22

Index

23

Contents

VLT® PTC Thermistor Card MCB 112

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

1 Introduction

1.1 Purpose of the Manual

This manual provides information for safe installation and
commissioning of VLT® PTC Thermistor Card MCB 112 used
with a Danfoss VLT® frequency converter with Safe Torque
O (STO). The manual is intended for use by qualied
personnel only.

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

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

VLT® is a registered trademark.

1.2 Additional Resources

This manual is targeted at users already familiar with the
VLT® frequency converters. It is intended as a supplement
to the manuals and instructions available for download at
vlt-drives.danfoss.com/Support/Technical-Documentation/.
Read the instructions shipped with the frequency
converter and/or frequency converter option before
installing the unit, and observe the instructions for safe
installation.

1.3

Document and Software Version

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

Edition Remarks

MG33V3xx Replaces MG33V2xx.

Editorial changes.

Now covering the complete system.

Table 1.1 Document Version

1.4

Products Covered

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

•

VLT® HVAC Drive FC 102.

•

VLT® AQUA Drive FC 202.

•

VLT® AutomationDrive FC 302.

1.5 Functional Overview

1.5.1 Intended Use

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

•

Protect electrical motors against inadmissible
heating due to overload.

•

Protect explosion-protected motors in explosive
atmospheres caused by gases, vapours, or mists,
Zone 1 and Zone 2, and/or in explosive
atmospheres caused by dust, Zone 21 and Zone

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

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

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

NOTICE

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

Introduction Operating Instructions

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1

1

1.5.1.1 Markings of the Frequency
Converter

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

MS 220 DA / MCB112

Code no.: 130B1137

Motor protection inside

See manual

for additional instruction

PTB 14 ATEX 3012U

CAUTION:

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

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

ε

130BE103.10

Illustration 1.1 Label to Apply to Frequency Converter

1.5.2

Foreseeable Misuse

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

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

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

WARNING

EXPLOSION DANGER

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

•

Zone 1/21.

•

Zone 2/22.

1.5.3 Thermal Motor Protection

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

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

1.5.4 ATEX ETR Thermal Monitoring

NOTICE

The ATEX ETR thermal monitoring function only applies
to Ex-e and Ex-n motors and is only available for VLT

®

AutomationDrive FC 302 frequency converters.

The FC 302 with

rmware version V6.3x or higher is
equipped with an ATEX ETR thermal monitoring function
for operation of Ex-e motors according to EN 60079-7 and
Ex-n motors according to EN 60079-15. Combined with an
ATEX-approved PTC monitoring device like MCB 112, the
installation does not need an individual approval from an
approbated organisation, that there is no need for
matched pairs.

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

1.5.5

Tripping Function

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

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

1.5.6

Safe Separation

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

1.5.7

Safe Disconnection Principle

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

Introduction

VLT® PTC Thermistor Card MCB 112

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

1

Frequency Converter

Logic
Out

Control Card

Potentially explosive

atmosphere

PTC-Sensors

3~ Ex-Motor

Safe Channel T37

Safe Stop
T37

T1

TP TP

T2

+24 V

PTC Thermistor Card
MCB 112

Non-explosive hazard zone

91
92
93

96
97
98

Converter module

130BE102.10

DI

Illustration 1.2 Block Diagram of the System

1.6 Motor Requirements

1.6.1 Motor Limits and Rules

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

•

Minimum switching frequency.

•

Maximum current.

•

Minimum motor frequency.

•

Maximum motor frequency.

Furthermore, respect the following:

•

Do not exceed the maximum allowable ratio
between frequency converter size and motor size.
The typical value is I

VLT, n

≤2xI

m,n

.

•

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

•

Multi-motor applications are not allowed. Only
connect 1 motor to the frequency converter.

1.6.2

Additional Motor Requirements

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

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

NOTICE

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

•

Only operate explosion-protected 3-phase motors
with frequency converters, if the motors are built,
tested, approved, and labelled separately for this
mode.

•

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

•

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

1.7

Approvals and Certications

Certication number:
PTB 14 ATEX 3012U

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

Introduction

Operating Instructions

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1

1.8 Symbols, Abbreviations, and
Conventions

Abbreviation Description

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

Table 1.2 Abbreviations

AbbreviationReference Description

ATEX ATEX Directive

94/9/EC

ATmosphere EXplosibles

HFT EN IEC 61508 Hardware fault tolerance: HFT=n

means that n+1 faults could cause a
loss of the safety function.

PDS/SR EN IEC

61800-5-2

Power drive system (safety-related).

PFD EN IEC 61508 Average probability of failure on

demand, value used for low­demand operation.

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

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

SIL EN IEC 61508

EN IEC 62061

Safety integrity level.

STO EN IEC

61800-5-2

Safe Torque O.

SRECS EN IEC 62061 Safety-related electrical control

system.

Table 1.3 Abbreviations Related to Functional Safety

Conventions

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

•

Cross-reference.

•

Link.

•

Parameter name.

Introduction

VLT® PTC Thermistor Card MCB 112

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

1