Vacon NX User manual

vacon® nx
ac drives
opt-af
safe torque off &
atex option board
user manual
vacon • 1
1.
2.
2.1.
3.
3.1.
3.2.
3.3.
3.3.1.
3.3.2.
3.3.3.
3.3.4.
3.4.
3.4.1.
3.4.2.
3.4.3.
3.4.4.
3.5.
3.5.1.
3.5.2.
3.5.3.
3.5.4.
3.5.5.
3.5.6.
3.6.
3.6.1.
4.
4.1.
4.1.1.
4.1.2.
4.2.
4.2.1.
4.2.2.
4.2.3.
4.2.4.
4.2.5.
4.2.6.
TABLE OF CONTENTS
Document ID:DPD00891B
Revision release date: 19.12.2012
GENERAL ........................................................................................................2
INSTALLATION OF THE OPT-AF BOARD ........................................................10
OPT-AF Board layout......................................................................................................12
STO AND SS1 SAFETY FUNCTIONS................................................................13
Safe Torque Off (STO) principle......................................................................................14
Safe Stop 1 (SS1) principle .............................................................................................15
Technical details ............................................................................................................17
Response times..............................................................................................................17
Connections....................................................................................................................17
Safety-related data according to the standard .............................................................18
Technical data ................................................................................................................20
Wiring examples.............................................................................................................21
Example 1: OPT-AF board without reset for Safe Torque Off (STO) .............................21
Example 2: OPT-AF board with reset for Safe Torque Off (STO) or
EN 60204-1 stop category 0...........................................................................................22
Example 3: OPT-AF board with external safety relay module with or without
reset for Safe Torque Off (STO) or EN 60204-1 stop category 0 ...................................23
Example 4: OPT-AF board with external time delayed safety relay
for Safe Stop 1 (SS1) or EN 60204-1 stop category 1....................................................24
Commissioning...............................................................................................................26
General wiring instructions ...........................................................................................26
Examples of cable sealing grommets or glands...........................................................26
Checklist for commissioning the OPT-AF board ...........................................................28
Parametrizing the drive for the Safe Torque Off (STO) safety functions ......................29
Parametrizing the drive and the external time delayed safety relay
for Safe Stop (SS1) safety function ................................................................................30
Testing the Safe Torque Off (STO) or Safe Stop 1 (SS1) safety functions......................30
Maintenance ...................................................................................................................31
Faults related to the Safe Torque Off (STO) or Safe Stop 1 (SS1) safety functions ......31
THERMISTOR FUNCTION (ATEX) ...................................................................33
Technical data ................................................................................................................36
Functional description ...................................................................................................36
Hardware and connections ............................................................................................37
Commissioning...............................................................................................................39
General wiring instructions ...........................................................................................39
Parameter setting for ATEX function.............................................................................39
Short circuit monitoring.................................................................................................40
Exceptional use of thermistor function on OPT-AF board (similar to OPT-A3,
not in compliance with ATEX directive 94/9/EC) ...........................................................40
OPT-AF board parameter ..............................................................................................41
Fault diagnosis of thermistor function ..........................................................................42
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vacon • 2
1.
GENERAL
GENERAL
This document covers OPT-AF option board VB00328H (or newer) and NXP Control board VB00761B
(or newer).
The OPT-AF option board together with NXP control board provides the following safety functions
with NX family products.
Safe Torque Off (STO)
Hardware based ‘Safe Torque Off’ safety function to prevent the drive from generating torque
on the motor shaft. STO safety function has been designed for use in accordance with the
following standards:
• EN 61800-5-2 Safe Torque Off (STO) SIL2
• EN ISO 13849-1: 2006 PL “d” Category 3
• EN 62061: 2005 SILCL2
• IEC 61508: 2000 SIL2
• The function also corresponds to an uncontrolled stop in accordance with stop category 0,
EN 60204-1: 2006.
• EN 954-1, Category 3
The STO safety function has been certified by IFA*
Safe Stop 1 (SS1)
SS1 safety function is realized in compliance with type C of the drives safety standard EN
61800-5-2 (Type C: “The PDS(SR) initiates the motor deceleration and initiates the STO
function after an application specific time delay”). 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: 2006 PL"d" Category 3
• EN 62061: 2005 SILCL2
• IEC 61508: 2000 SIL2
• The function also corresponds to a controlled stop in accordance with stop category 1, EN
60204-1: 2006.
The SS1 safety function has been certified by IFA *
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 OPT-AF board are described in this user's manual. The OPT-AF option
board contains also two programmable output relays. (Note! Not part of any safety function.)
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 the OPT-AF board do not comply with Emergency Switching Off according to EN 60204-1.
* IFA = Institut für Arbeitsschutz der Deutsche Gesetzlichen Unfallversicherung, Germany
** VTT = Technical Research Centre of Finland
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GENERAL
vacon • 3
5
EC DECLARATION OF CONFORMITY
Manufacturer's name:
Vacon Plc
Manufacturer's address:
P.O.Box 25
Runsorintie 7
FIN-65381 Vaasa
Finland
We hereby declare that the safety functions of the following product
Product name:
Vacon OPT-AF option board to be used with Vacon NXP control
board in NX family products
Product Identification
OPT-AF option board, VB00328H (or newer revision)
NXP control board, VB00761B (or newer revision)
Product Safety Functions
Safe Torque Off, Safe Stop 1 (Specified in EN 61800-5-2:2007)
fulfils all of the relevant safety component requirements of EC Machinery Directive 2006/42/EC.
Notified body that carried out the EC type examination:
IFA – Institute for Occupational Safety and Health of the German Social Accident Insurance
Testing and Certification Body in BG-PRÜFZERT
Alte Heerstraße 111
D-53757 Sankt Augustin
Germany
European notified body, Identification number 0121
IFA Certificate No: IFA 1001221
The following standards and/or technical specifications referenced below were used:
EN ISO 13849-1:2006
Safety of machinery – Safety-related parts of the control systems. Part 1: General principles for design
EN ISO 13849-2:2006
Safety of machinery – Safety-related parts of the control systems. Part 2: Validation
EN 60204-1:2006
Safety of machinery – Electrical equipment of machines – Part 1: General requirements
EN 61800-5-2:2007
Adjustable speed electrical power drive systems – Part 5-2: Safety requirements - Functional
IEC 61508:2000
Functional safety of electrical/electronic/programmable electronic safety-related systems – Parts 1-7
EN 62061:2005
Safety of machinery – Functional safety of safety-related electrical, electronic and programmable
electronic control systems
Signature
Authorised representative
In Vaasa, 28.08. 2010
Vesa Laisi
Janne Kuivalainen
President and CEO
Director, Control Platform and Products
SGI
1
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1
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GENERAL
11050.emf
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GENERAL
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vacon • 5
1
vacon • 6
1
GENERAL
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GENERAL
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vacon • 7
1
vacon • 8
GENERAL
11049.pdf
1
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INSTALLATION OF THE OPT-AF BOARD
2.
vacon • 10
INSTALLATION OF THE OPT-AF BOARD
MAKE SURE THAT THE FREQUENCY CONVERTER IS SWITCHED OFF
BEFORE AN OPTION OR FIELDBUS BOARD IS CHANGED OR ADDED!
!
NOTE
A
Vacon NXP frequency converter with IP54 enclosure.
B
Remove the main cover.
C
Open the cover of the control unit.
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2
vacon • 11
INSTALLATION OF THE OPT-AF BOARD
D
Install OPT-AF option board in slot B on the control
board of the frequency converter.
Make sure that the grounding plate fits tightly
in the clamp.
E
Cable installation:
STO and SS1 safety functions require the use
of cable sealing grommets or glands for all cables
in the drive. The grommets or glands must be
suitable for the type and amount of cables used
and they shall fulfil IP54 requirements.
See the User´s Manual for hole sizes for the Power
cables. The hole size is PG21 (28,3 mm) for the
control cables.
See Chapter 3.5.2 for examples of cable sealing
grommets or glands that can be used.
F
Close the cover of the control unit and attach the main
cover. Before attaching the main cover, check that the
gasket of the cover is not damaged for IP54 units. Use
a tightening torque of 0,9...1,1 Nm for the main cover
screws.
NOTE! You can download the English and French product manuals with applicable safety,
warning and caution information from www.vacon.com/downloads.
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 www.vacon.com/downloads.
2
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INSTALLATION OF THE OPT-AF BOARD
2.1
vacon • 12
OPT-AF Board layout
STO inputs two
independent channels
Thermistor input
Thermistor Input: Thermistor
active > 4000 ohm. After being
active, the fault can be reset if
resistance is < 2000 ohm.
Jumper X10 for selecting
thermistor short
circuit supervision
+24V+
+24V+24V+
SD1
SD2
+24VProgrammable
Relay
"NO"
Programmable
Relay
"NO/NC"
Jumper wire X12
See Chapter 4.2.4.
11052.emf
Figure 1. The layout of the OPT-AF board
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vacon • 13
3.
STO AND SS1 SAFETY FUNCTIONS
STO AND SS1 SAFETY FUNCTIONS
The safety functions of the OPT-AF board, such as the technical principle and data, wiring examples
and commissioning, will be described in this chapter.
NOTE! Designing of safety-related systems requires speial knowledge and
skills. Only qualified persons are permitted to install and set up the OPT-AF
board.
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 sy-stem is safe. Safety devices like the OPT-AF 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 EN 12100 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 OPT-AF option board provides together with NXP
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.
CAUTION! The OPT-AF 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 e.g. using an external supply
disconnecting switch. See for e.g. EN 60204-1 section 5.3.
CAUTION! If STO or SS1 safety function is required in DriveSynch installation, please contact Vacon for more information.
CAUTION! In LineSynch application the use of OPT-AF board will not fulfill
STO or SS1 -safety functions while the drive is in by-pass mode.
3
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STO AND SS1 SAFETY FUNCTIONS
3.1
vacon • 14
Safe Torque Off (STO) principle
The STO safety function of the OPT-AF board allows the drive output to be disabled so that the drive
cannot generate torque in the motor shaft. For STO, the OPT-AF board has two separate, galvanically isolated inputs SD1 and SD2.
Note! Both SD1 and SD2 inputs are normally closed for the drive to be in enable state.
The STO safety function is achieved by disabling the drive modulation. The drive modulation is disabled through two independent paths controlled by SD1 and SD2 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 Figure 2.
If either of the STO inputs is not connected to a +24 V signal, the drive will not go to the RUN state.
NXP CONTROL UNIT
OPT-AF board, slot B
Thermistor
+
Control board
Atex Safety
Function
-
SD1+
MICROCONTROLLER
Hardware
Safe Torque Off
1
SD1-
SD2+
Hardware
Safe Torque Off
2
SD2-
RO1/3
RO1/1
RO1/2
RO2/3
RO2/2
Relays only for operational use,
not part of the safety functions
PWM control
POWER UNIT
=
3~
M
11053.emf
Figure 2. STO safety function principle in NXP frequency converter with the OPT-AF board
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3.2
STO AND SS1 SAFETY FUNCTIONS
Safe Stop 1 (SS1) principle
The Safe Stop 1 (SS1) safety function initiates the motor deceleration and initiates the STO after a
(user set) time delay.
Frequency
Stop
Motor deceleration
factual
Safe Torque Off (STO)
Time delay
0
Time
11054.emf
Figure 3. 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 4.
Safe Stop 1 (SS1)
Time Delayed Safety Relay
Vacon NX Safe Torque Off (STO)
Subsystem Safety Relay
Subsystem STO
+
11055.emf
Figure 4. Safe Stop 1 (SS1) safety function
3
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STO AND SS1 SAFETY FUNCTIONS
vacon • 16
Figure 5 shows the connection principle of Safe Stop 1 safety function.
-
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
NX drive. The general digital input must be programmed to detect the drive stop command
and initiates without time delay the drive stop function (must be set to "stop by ramp") and
causes motor deceleration.
Safety Relay
with timer
Ramp stop
Switch
OPTAx
OPTBx
Digital input
NXP control
OPT-AF
Time
Delay
STO
STO ch1
STO ch2
Power Unit
M
11056.emf
Figure 5. The connection principle of Safe Stop 1 (SS1)
CAUTION! The system designer/user is responsible of understanding and
setting the time delay of the safety relay, due to the fact it is process/
machine dependent.
→ The time delay must be set to a greater value than the deceleration
time of 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.
See Chapter 3.5.5 concerning the parametrizing of Safe Stop 1 and Chapter 3.4.4 "Example 4" for
the wiring of Safe Stop 1.
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STO AND SS1 SAFETY FUNCTIONS
3.3
Technical details
3.3.1
Response times
Safety function
Activation time
De-activation time
Safe Torque Off
< 20 ms
1000 ms
Safety Function
Delay from stop signal at safety relay Time delay for Safe Torque Off (STO)
input until activation of ramp stop
activation
Safe Stop 1 (SS1)
Safety relay delay + typ. 20 ms
System process dependent. User set(drive)
table through the safety relay timer.
NOTE! Drive application software
dependent. Refer to the user manual
of the application in use.
3.3.2
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 X10 in "OFF" state. The termistor input operation and instructions
are presented in Chapter 4.
I/O terminals on OPT-AF
Table 1. OPT-AF I/O terminals
Terminal
1
SD1+
2
SD1-
3
SD2+
4
SD2-
21 RO1/normal closed
22 RO1/common
23 RO1/normal open
Parameter reference
on keypad and
NCDrive
DigIN:B.2
DigIN:B.3
DigOUT:B.1
25 RO2/common
26 RO2/normal open
Technical information
Isolated STO input 1
Virtual GND 1
Isolated STO input 2
Relay output 1 (NO/NC) *
Switching capacity
24 VDC/8 A
250 VAC/8 A
125 VDC/0.4 A
Min. switching load
5 V/10 mA
Relay output 2 (NO) *
Switching capacity
Min. switching load
DigIN:B.1
+24 V +-20% 10... 15 mA
Virtual GND 2
DigOUT:B.2
28 TI1+
29 TI1-
+24 V +-20% 10... 15 mA
24 VDC/8 A
250 VAC/8 A
25 VDC/0.4 A
5 V/10 mA
Thermistor input; Rtrip > 4.0 kΩ (PTC)
* If 230 VAC 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. Refer to standard EN 60204-1, section 7.2.9.
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STO AND SS1 SAFETY FUNCTIONS
3.3.3
vacon • 18
Safety-related data according to the standard
Safe Torque Off (STO) safety-related data
EN 61800-5-2:2007
SIL 2
PFH = 2,98 x 10-9 /hour
Dual Channel Structure
EN 62061:2005
SIL CL 2
PFH = 2,98 x 10-9 /hour
Dual Channel Structure
EN/ISO 13849-1:2006
PL d
PFH = 2,98 x 10-9 /hour
Category 3
IEC 61508:2000
High Demand Mode
SIL 2
PFH = 2,98 x 10-9 /hour
Dual Channel Structure
IEC 61508:2000
Low Demand Mode
SIL 2
PFDAVG = 2,61 x 10-4
TM = 20 years
Dual Channel Structure
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3
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STO AND SS1 SAFETY FUNCTIONS
Safe Stop (SS1) safety-related data
The SS1 safety function consists of two subsystems with different safety-related data.
The subsystem consisting of the time delayed safety relay is manufactured by PHOENIX CONTACT
and of type:
-
PSR-SCP-24DC/ESD/5X1/1X2/300 or
PSR-SPP-24DC/ESD/5X1/1X2/300
See manufacturer user manual (by ID "2981428 or "2981431") for more information regarding the
time delayed safety relay.
PSR-SC/PP-24DC/ESD/5X1/1X2 300 safetyrelated data from user manual and certificate:
NX STO safety-related data:
IEC 61 508
SIL 2
EN 61800-5-2:2007 SIL 2
EN 62061
SIL CL 2
EN 62061:2005
SIL CL 2
DIN EN/ISO 13849-1
PL d
Category 3
IEC 61508:2000
SIL 2
PFH
1,89 x 10-9 /hour
DIN EN/ISO 138491:2006
PL d
Category 3
PFH
2,98 x 10-9 /hour
SubsystemSafety Relay
+
SubsystemNX STO
Safe Stop 1 (SS1) safety-related data:
→
EN 61800-5-2:2007
SIL 2
EN 62061:2005
SIL CL 2
IEC 61508:2000
SIL 2
DIN EN/ISO 13849-1:2006
PL d
Category 3
PFH
4,87 x 10-9 /hour
-
For combining the two subsystems, the maximum safety integrity level or performance level
reached is the lowest of a subsystem.
→ SIL 2 or PL d
- The PFH value for a safety function of combined subsystems is the sum of all subsystems
PFH values.
PFHSS1 = PFHSafety Relay + PFHNX STO = 1,89 x 10-9 /hour + 2,98 x 10-9 /hour = 4,87 x 10-9 /hour
→ The result is within the requirements for SIL 2 or PL d (PFH is even within the requirements
for up to SIL 3/PL e).
3
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STO AND SS1 SAFETY FUNCTIONS
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Abbreviations or safety parameters definitions
SIL
Safety Integrity Level
PL
Performance Level
PFH
Probability of a dangerous random hardware Failure per Hour
Category
Designated architecture for a safety function (from EN ISO 13849-1:2006)
PFDAVG
The average probability of (random hardware) failure on demand
TM
Mission time
3.3.4
Technical data
For more information, see the chapter "Technical data" in the product-specific user's manual.
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3.4
STO AND SS1 SAFETY FUNCTIONS
Wiring examples
The examples in this chapter show the basic principles for wiring OPT-AF board. Local norms and
regulations should be always followed in the final design.
3.4.1
Example 1: OPT-AF board without reset for Safe Torque Off (STO)
MAIN CIRCUIT
L1
L2
CONTROL UNIT
PE
L3
PE
1
3
5
2
4
6
F1
STOP
START
S7
S6
13
11
14
12
SPEED REFERENCE
CCW
R1
S
CW
W12
1sh
1r
2p
2s
1
2
3
1
2
+10Vref
AIA1+
PE
L1
L2
L3
2sh
PE
4
5
4
3
AIA2
­
7
8
9
10
11
12
13
14
18
7
8
9
10
11
12
13
14
15
16
17
18
DIN1
DIN2
DIN3
CMA
+24V
GND
DIN4
DIN5
DIN6
CMB
AOA1+
ABCD
X1
X2
SD2+
17
GND
SD2
­
RO1 NC
ABCD
X2
RO1 NO
RO1 C
ABCD
X3
RO2 C
RO2 NO
B
A
X6
TI1
­
TI1+
7
19
19
AOA1
­
20
20
DOA1
OPTA1
Basic I/O
SLOT A
2
SD1
­
16
6
X10
SD1+
15
+24V
5
AIA2+
AIA1
­
6
PE
OFF
X10
PE
U
V
W
1
2
3
4
21
22
23
25
26
29
28
OPT
­ AF
SLOT B
9
W10
1r
1b
2r
2b
Vacon
PE
PE
PE
START
res et
+
STO P
s elect
PE
enter
PE
PE
Safe disable
S1
11
21
12
22
W1
0V
U1
V1
W1
M
+24V
Short­circuit and
earth fault protected supply
3~
PE
1
2
M1
11057.emf
Figure 6. Example 1.
Figure 6 shows a connection example of OPT-AF board for Safe Torque Off safety function without
reset. The switch S1 is connected with 4 wires to the OPT-AF board as shown above.
The power supply to S1 may come from OPT-A1 board (connector pins 6 & 7 in Figure 6) or it may
also be external.
When the switch S1 is activated (contacts open), the drive will go to STO state and motor (if running)
will stop by coasting. The drive will indicate: "A30 SafeTorqueOff".
When switch S1 is released (contacts closed), the drive returns to the ready state. The motor can
then be run with a valid start command.
Note : All NXP series drives are programmed to accept only edge sensitive start command for a valid start from STO state. To start the motor operation, a new start command is required after the
drive returns to ready state.
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STO AND SS1 SAFETY FUNCTIONS
3.4.2
vacon • 22
Example 2: OPT-AF board with reset for Safe Torque Off (STO) or
EN 60204-1 stop category 0
MAIN CIRCUIT
L1
L2
CONTROL UNIT
PE
L3
PE
1
3
5
2
4
6
F1
STOP
START
RESET
S8
S7
S6
13
11
13
14
12
14
SPEED REFERENCE
CCW
R1
S
CW
W12
1sh
1r
2p
2s
1
2
3
1
2
3
4
5
6
+10Vref
AIA1+
AIA1
­
AIA2+
AIA2
­
+24V
PE
L1
L2
L3
2sh
PE
4
5
6
7
8
9
7
8
9
10
11
12
13
14
15
16
17
18
19
20
GND
DIN1
DIN2
DIN3
CMA
+24V
GND
DIN4
DIN5
DIN6
CMB
AOA1+
AOA1
­
DOA1
ABCD
X10
X1
X2
10
11
12
ABCD
X2
13
14
B
A
X6
2
SD1+
SD1
­
SD2+
SD2
­
RO1 NC
RO1 C
RO1 NO
RO2 C
RO2 NO
TI1+
7
16
17
18
19
20
OPTA1
Basic I/O
SLOT A
ABCD
X3
15
TI1
­
PE
OFF
X10
U
PE
V
W
1
2
3
4
21
22
23
25
26
28
29
OPT
­ AF
SLOT B
9
W10
PE
PE
PE
1r
1b
2r
2b
Vacon
START
res et
+
STOP
s elect
PE
enter
PE
PE
Safe disable
S1
W1
11
21
12
22
0V
+24V
U1
V1
W1
Short­circuit and
earth fault protected supply
M
3~
PE
1
2
M1
11058.emf
Figure 7. Example 2.
Figure 7 presents a connection example of OPT-AF board for STO safety function with reset. The
switch S1 is connected with 4 wires to the OPT-AF board as shown above. The digital input 3 (DIN3),
for example, is wired for the fault reset function. The reset function can be programmed to any of
the available digital inputs. The drive must be programmed to generate a fault in STO state.
The power supply to S1 may come from OPT-A1 board (connector pins 6 & 7 in Figure 6) or it may
also be external.
When the switch S1 is activated (contacts open), the drive will go to STO state and motor (if running)
will stop by coasting. The drive will indicate: "F30 SafeTorqueOff".
To start the motor operation again, following sequence is performed.
•
•
•
Release switch S1 (contacts closed). The hardware is now enabled but the drive continues to
display the fault "F30 SafeTorqueOff".
Acknowledge the releasing of switch by edge sensitive reset function. The drive returns to
the ready state.
Giving a valid start command will start running the motor.
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3
vacon • 23
STO AND SS1 SAFETY FUNCTIONS
Note : All NXP series drives are programmed to accept only edge sensitive start command for a valid start from STO state. To start the motor operation, a new start command is required after the
drive returns to ready state.
Note: For EN 60204-1 emergency stop according to stop category 0, use emergency stop button.
3.4.3
Example 3: OPT-AF board with external safety relay module with or
without reset for Safe Torque Off (STO) or
EN 60204-1 stop category 0
MAIN CIRCUIT
L1
L2
CONTROL UNIT
PE
L3
Alternative : Gate Switch *
PE
31
1
3
32
5
11
F1
S2
Open
2
4
12
STOP
START
13
SPEED REFERENCE
6
S3
14
R1
S7
S6
CCW
S
13
11
14
12
33
34
CW
W12
1sh
1r
PE
2sh
2p
2s
2
3
PE
1
L1
L2
L3
4
5
6
7
8
9
10
12
13
14
15
16
17
18
19
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
+10Vref
AIA1+
AIA1
­
AIA2+
AIA2
­
+24V
GND
DIN1
DIN2
DIN3
CMA
+24V
GND
DIN4
DIN5
DIN6
CMB
AOA1+
AOA1
­
ABCD
X10
2
11
X1
X2
SD1+
SD1
­
SD2+
SD2
­
RO1 NC
ABCD
X2
RO1 NO
RO1 C
RO2 C
B
A
RO2 NO
X6
TI1
­
TI1+
7
20
DOA1
OPTA1
Basic I/O
SLOT A
ABCD
X3
20
PE
OFF
X10
PE
U
V
OPT
­ AF
SLOT B
W
1
2
3
4
21
23
22
25
26
29
28
9
Vacon
START
res et
+
STOP
EXAMPLE:
DOLD BN5930.48/204­230VAC
PE
PE
PE
PE
PE
W3
s elect
enter
PE
ON
1r
S1
2r
A1
SafeDisable
A10
T11
T12
K3.1
13
14
T22
K1.2
X2
12
11
2
22
21
1
K1.1
K3.2
28
K2.2
23
K2.1
24
26
29
K1
K2
27
L1
230Vac
N
Short­circuit and
earth fault protected supply
K3
W1
A2
U1
V1
W1
M
PE
3~
PE
1
2
M1
S23
For automatic reset
link X2 and T22
(Not allowed with Emergency stop)
W1
0V
+24V
Short­circuit and
earth fault protected supply
11059.emf
Figure 8. Example 3.
Figure 8 presents a connection example of OPT-AF board for STO safety function with external
safety relay module and without reset.
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 OPT-AF board with 4 wires as
shown in Figure 8.
When the switch S1 is activated (contacts open), the drive will go to STO state and motor (if running)
will stop by coasting. The drive will indicate: "A30 SafeTorqueOff".
When switch S1 is released (contacts closed), the drive returns to the ready state. The motor can
then be run with a valid start command.
The external relay can be wired so that manual reset is required to reset the STO safety function.
3
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STO AND SS1 SAFETY FUNCTIONS
vacon • 24
More information regarding the safety relay module may be found from the safety relay documentation.
Note : All NXP series drives are programmed to accept only edge sensitive start command for a valid start from STO state. To start the motor operation, a new start command is required after the
drive returns to ready state.
Note: For EN 60204-1 emergency stop according to stop category 0, use emergency stop button.
* Switch S1 in the figure can be replaced with the gate switch, then only Safe torque off mode is required. In
normal operation, both contacts are closed.
3.4.4
Example 4: OPT-AF board with external time delayed safety
relay for Safe Stop 1 (SS1) or EN 60204-1 stop category 1
MAIN CIRCUIT
L1
L2
L3
CONTROL UNIT
PE
PE
1
3
5
2
4
6
F1
STOP
START
3F RS2
S7
S6
CCW
R1
RAMP STOP
RS1 ­3E
SPEED REFERENCE
S
13
11
14
12
CW
+04­W12
1sh
1r
2p
2s
1
2
3
1
2
3
4
5
6
+10Vref
AIA1+
AIA1
­
AIA2+
AIA2
­
+24V
PE
L1
L2
2sh
PE
L3
4
5
6
7
8
9
7
8
9
10
11
12
13
14
15
16
17
18
19
GND
DIN1
DIN2
DIN3
CMA
+24V
GND
DIN4
DIN5
DIN6
CMB
AOA1+
AOA1
­
ABCD
X10
X1
X2
10
11
12
ABCD
X2
13
14
15
16
17
X6
2
SD1+
SD1
­
SD2+
SD2
­
RO1 NC
RO1 NO
RO1 C
RO2 C
RO2 NO
TI1+
7
19
20
20
DOA1
OPTA1
Basic I/O
SLOT A
ABCD
B
A
X3
18
TI1
­
PE
OFF
X10
PE
U
V
W
1
2
3
4
21
22
23
25
26
28
29
OPT
­ AF
SLOT B
9
Vacon
PE
START
PE
PE
res et
+
STO P
PE
PE
W3
A10
1r
4B RS1
s elect
PE
24VDC
S1
S10
11
21
12
22
RESET
enter
Bridge between S33/S35 for automatic reset.
(Not allowed with emergency stop)
2r
57
67
13
23
33
41
+
A1
58
68
14
24
34
42
A2
S11
S12 S21 S22
S33
S34 S35
PHOENIX CONTACT
PSR
­ SC
P ­ 24DC/ESD/5X1/1X2/300 (With screw connection)
OR
PSR
­ SC
P ­ 24DC/ESD/5X1/1X2/300 (With spring­ cage connection)
0VDC
U1
V1
W1
RS2 ­6B
W1
PE
M
3~
PE
1
0V
2
M1
+24V
Short­circuit and
earth fault protected supply
11060.emf
Figure 9. Example 4.
Figure 9 presents a connection example of OPT-AF board for STO safety function with external time
delayed safety relay module for realizing the Safe Stop 1 or EN 60204-1 Stop Category 1.
External safety relay module is connected to the switch S1. The safety relay module is connected to
OPT-AF board with 4 wires as shown in Figure 9. The time delay settings of the safety relay must
correspond to the application requirements.
24-hour support +358 (0)201 212 575 • Email: [email protected]
3
vacon • 25
STO AND SS1 SAFETY FUNCTIONS
When the switch S1 is activated, the safety relay module will immediately activate DIN6, which in
turn activates the STOP command to the drive. The STOP function is programmed to "Stop by
Ramp". The safety relay activates the Safe Torque Off state after the time delay has expired. The
time delay is set more than the deceleration time set in the drive to stop by ramp from maximum
speed. The drive will indicate: "A30 SafeTorqueOff".
When the switch S1 is released (contacts closed), the drive returns to ready state. The motor can
then be run with a valid start command.
The external relay can be wired so that manual reset is required to reset the STO safety function.
More information regarding the safety relay module may be found from the safety relay datasheet.
Note: All NXP series drives are programmed to accept only edge sensitive start command for a valid
start from STO state. To start the motor operation, a new start command is required after the drive
returns to ready state.
3
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STO AND SS1 SAFETY FUNCTIONS
3.5
vacon • 26
Commissioning
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. See also the warnings on page 13.
3.5.1
•
•
•
•
General wiring instructions
The wiring should be done according to the general wiring instructions for the specific product where OPT-AF is installed.
Shielded cable is required for connecting the OPT-AF board.
EN 60204-1 part 13.5: The voltage drop from supply point to load should not exceed 5%.
In practice, due to electromagnetic disturbances, the cable length should be limited to 200 m
max. In a noisy environment, the length of the cable could still be less than 200 m.
Table 2. Example of cable types
Example of cable types
Name
KJAAM
JAMAK
RFA-HF(i)
LiYDY-CY TP
3.5.2
Conductors
2x(2+1)x0,5 mm²
2x(2+1)x0,5 mm²
2x(2+1)x0,5 mm²
2x(2+1)x0,5 mm²
Manufacturer
Reka
Draka NK Cables Oy
Helkama
SAB Bröckskes
Examples of cable sealing grommets or glands
Below you can see examples of cable sealing grommets or glands. Refer to the listed manufacturers or corresponding manufacturers for more information on correct types that are suiteable for
the hole and cable diameter:
11061.emf
Figure 10. VET membrane glands from Oy Mar-Con Polymers Ltd
11062.emf
Figure 11. Cable gland, polystyrene from WISKA Hoppmann & Mulsow GmbH,
CABLE ACCESSORY SYSTEMS
24-hour support +358 (0)201 212 575 • Email: [email protected]
3
vacon • 27
STO AND SS1 SAFETY FUNCTIONS
11063.emf
Figure 12. QUIXX membrane for several cables from WISKA Hoppmann & Mulsow GmbH,
CABLE ACCESSORY SYSTEMS. Note! A metric to PG adapter is needed.
11064.emf
Figure 13. SNAP -PG cable grommet from
A. Vogt GmbH & Co. KG (gummivogt)
11065.emf
Figure 14. UNI Dicht cable glands for multiple cables from PFLITSCH GmbH
11066.emf
Figure 15. Cable gland model "PERFECT" with multiple sealing insert from Jacob GmbH.
3
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STO AND SS1 SAFETY FUNCTIONS
3.5.3
vacon • 28
Checklist for commissioning the OPT-AF board
The minimum steps required during connecting the Safe Torque Off (STO) or Safe Stop 1 (SS1) safety functions of the OPT-AF board are shown in the checklist below. For ATEX related issues see the
ATEX section.
Table 3. Checklist for commissioning the STO or SS1 safety functions.
Nr
Step
1
Has a risk assessment of the system been carried out to ensure that
using the OPT-AF board Safe Torque Off (STO) or Safe Stop 1 (SS1) safety
function is safe and according to local regulations?
2
Does the assessment include an examination of whether using external
devices such as a mechanical brake is required?
3
Switch S1
- Has the switch S1 been chosen according to the required safety
performance target (SIL or PL) set during the risk evaluation?
- Is the switch S1 required to be lockable or otherwise secured in
the isolating position?
- Is it ensured that color coding and marking is in accordance with
the intended use?
- Is the external power supply earth fault and short circuit protected
(EN 60204-1)?
4
Is the reset function edge sensitive?
If a reset function is used with Safe Torque Off (STO) or Safe Stop 1 (SS1) it
must be edge sensitive.
5
The shaft of a permanent magnet motor might in an IGBT fault situation
rotate up to 360 degrees / pole of the motor. Has it been ensured that the
system designed in such a way that the this can be accepted?
6
Have process requirements (including deceleration time) been considered for correct execution of Safe Stop 1 (SS1) safety function and are the
corresponding settings done according to Chapter ?
7
Is the enclosure class of the control unit, where the OPT-AF board is
installed, at least IP54? According to ISO13849-2 and table D5, PCBs containing safety related functions require a fault exclusion for short-circuit
between two adjacent pads/tracks. This is realized with IP54 enclosure.
8
Have the User's Manual instructions for the specific product, on EMC
compliant cabling been followed?
9
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?
10
Have only approved units and parts been used?
11
Is the NXP control board VB00761 revision B or newer? (See the sticker
on the NXP control board).
12
Is the NXP system software version NXP00002V179, or newer?
13
Has a routine been set up to ensure that the functionality of the safety
function is being checked at regular intervals?
14
Has this manual been read, understood and followed carefully?
24-hour support +358 (0)201 212 575 • Email: [email protected]
No
Yes
3
vacon • 29
3.5.4
STO AND SS1 SAFETY FUNCTIONS
Parametrizing the drive for the Safe Torque Off (STO)
safety functions
There are no parameters for the STO function itself.
In applications, there is a possibility to change the warning A30 "SafeTorqueOff" to a fault. For example in NXP Multi Purpose application through parameters  protections  SafeDisable mode,
the STO state may be changed to generate a fault. As default, it is always set to generate a warning.
NOTE! When STO state is changed to indicate a fault, the drive will display the fault "F30 SafeTorqueOff" even after the switch S1 have been released (contacts closed) and the hardware is enabled. The fault must be acknowledged.
In application, there is also a possibility to indicate the STO state. This can be done through a digital
output.
For example the NXP multi purpose application provides the user with this possibility. The
indication of STO state could be parametrized to one of the relays on OPT-AF board (B1 or B2). The
parameter for providing this feedback can be found in: parameters  output signals  dig out
signals  SafeDisableactiv.
NOTE! The feedback or indication of the STO state is NOT part of the Safety functions.
OPT-AF board parameter:
3
Code
Parameter
Default
Note
P7.2.1.2
Start-Up Prev
“Fault”
To start the motor operation, after a thermistor fault,
an edge sensitive start command is required after the
drive returns to ready state.
a)
When OPT-AF board parameter "Start-Up
Prev" is "Fault", the drive will generate a
"F26 Start-Up Prev" fault if start command is
on, when returning to ready state after a
thermistor fault has been active. The drive
can be started with an edge sensitive start
command after fault reset.
b)
When OPT-AF board parameter "Start-Up
Prev" is "Warning", the drive will generate a
"A26 Start-Up Prev" warning if start command is on, when returning to ready state
after a thermistor fault has been active. The
drive can be started with an edge sensitive
start command. No fault reset is required in
this case.
c)
When OPT-AF board parameter "Start-Up
Prev" is "No action", the drive will not generate any indication. The drive can be started
with an edge sensitive start command. No
fault reset is required in this case.
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STO AND SS1 SAFETY FUNCTIONS
3.5.5
vacon • 30
Parametrizing the drive and the external time delayed safety relay
for Safe Stop (SS1) safety function
Safe Stop 1 requires setting of time delay on the external safety relay component:
•
Requirement: The time delay setting needs to be greater than the deceleration time set in
the drive
NOTE! See manufacturer user manual for more information regarding the setting of the time delay.
Safe Stop 1 safety function requires that the drive is configured according to the following guidelines:
•
•
•
Deceleration time must be set according to the machine or process requirement
The drive stop function must be programmed to "stop by ramp"
A dedicated digital stop input must be used (not combined with start command) for the drive
stop command
See the previous chapter for parametrizing the drive for Safe Torque Off (STO) safety function.
NOTE! The drive will indicate Safe Torque Off (STO) state when Safe Stop 1 time delay has expired
NOTE! If the time delay (of the external safety relay component) is NOT set correctly (time delay set
shorter than the required deceleration time of the process/machine), the motor will stop by coasting when the time delay expires.
3.5.6
Testing the Safe Torque Off (STO) or Safe Stop 1 (SS1)
safety functions
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! Before testing the STO or SS1 safety functions, make sure that the checklist (Table 3) is inspected and completed.
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.
When the STO safety function is activated, a code: A30 "SafeTorqueOff " appears on the control keypad display. This indicates that the STO safety function is active. After STO has been deactivated, the
warning remains active for 10 seconds.
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3
vacon • 31
3.6
STO AND SS1 SAFETY FUNCTIONS
Maintenance
CAUTION! If any service or repair is to be conducted on the drive installed
with OPT-AF board please follow the check list given in Chapter 3.5.3.
CAUTION! During maintenance breaks, or in case of service/repair, the OPT-AF
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 3.5.6.
3.6.1
Faults related to the Safe Torque Off (STO) or Safe Stop 1 (SS1)
safety functions
Table 4 shows the normal warning / alarm, generated when STO safety function is active.
Table 4. Warning/alarm indicating that STO safety function is active
Fault code
Warning
Subcode
30
SafeTorqueOff
1
Possible cause
Correcting measures
STO inputs SD1 & SD2 are
activated through the OPTAF option board.
Table 5 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, the fault may NOT be reset.
Table 5. Single hardware problems detected in the STO safety function
Fault code
Fault
Subcode
8
System Fault
30
8
3
System Fault
31
Possible cause
Correcting measures
STO inputs are in different state. This fault
occurs when the SD
inputs are in different
state more than 5 seconds.
-
Thermistor short circuit
detected.
-
-
Check the S1 switch.
Check the cabling to
the OPT-AF board
Single hardware
problem possible in
either OPT-AF board
or NXP control
board.
Correct the cabling
Check the jumper for
the thermistor short
circuit supervision, if
thermistor function
is not used, and the
thermistor input is
short circuited.
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STO AND SS1 SAFETY FUNCTIONS
vacon • 32
Table 5. Single hardware problems detected in the STO safety function
Fault code
Fault
Subcode
Possible cause
8
System Fault
32
OPT-AF board has been
removed.
-
It is not allowed to
remove the OPT-AF
board once it has
been reqognized by
the software. NOTE!
There is only one
method to clear this
fault. By writing
"OPT-AF Removed"
to "1" and then back
to "0" again. This
variable is found
from the "System
Menu" "Security"
(6.5.5).
8
System Fault
33
OPT-AF board EEPROM
error (checksum, not
answering…).
-
Change the OPT-AF
board.
8
System Fault
34...36
OPT-AF supply voltage
hardware problem
detected.
-
Change the OPT-AF
board.
8
System Fault
37...40
Single hardware problem
detected in STO inputs.
-
Change the OPT-AF
board or the NXP
control board.
8
System Fault
41...43
Single hardware problem
detected in the thermistor input.
-
Change the OPT-AF
board.
8
System Fault
44...46
Single hardware problem
detected in STO inputs or
in the thermistor input.
-
Change the OPT-AF
board or the NXP
control board.
8
System Fault
47
OPT-AF board mounted in
old NXP control board.
-
Change the NXP
control board to
VB00561, rev. H or
newer.
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Correcting measures
3
vacon • 33
4.
THERMISTOR FUNCTION (ATEX)
THERMISTOR 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 wich 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
11070.emf
It can be used as an overtemperature tripping device for motors in explosive area (EX motors).
Note: The OPT-AF board also contains the Safe Torque Off (STO) safety function. When STO is not
intended to be used, inputs SD1+(OPT-AF: 1) ,SD2+(OPT-AF:3) are to be connected to +24 V (e.g.
OPT-A1:6) & SD1-(OPT-AF:2) .SD2- (OPT-AF:4) are to be connected to GND(for e.g. OPT-A1:7).
NOTE!
Safety devices like the OPT-AF board must be correctly incorporated into the entire
system. The functionality of the OPT-AF 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. Maximum SIL capability of this function in the drive is
SIL1.
CAUTION! The information in this manual provides guidance on the use of thermistor function for protecting overheating of motors in explosive atmosphere. This
information is ensured to be correct and 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.
CAUTION! During maintenance breaks, or in case of service/repair the OPT-AF
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 OPT-AF board with NXP control is used to
protect the overheating of motors in explosive atmosphere. The drive itself including
OPT-AF board can not be installed in explosive atmosphere.
NOTE! Special conditions required for safe use (X in the certificate number):
This function can be used 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. E.g. in Exe- and ExnAmotors PTC sensors shall be certified together with the motor according to the
requirements of the type of protection.
The allowed ambient temperature range for the drive is -10 ºC…+50 ºC.
Note: Changes in this chapter are only allowed with the permission of certification body.
4
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THERMISTOR FUNCTION (ATEX)
vacon • 34
EU DECLARATION OF CONFORMITY
We
Manufacturer's name:
Vacon Oyj
Manufacturer's address:
P.O.Box 25
Runsorintie 7
FIN-65381 Vaasa
Finland
hereby declare that the product
Product name:
Vacon OPTAF (VB00328) to be used with Vacon NXP control unit
(VB00561H, VB00661A or VB00761B or later)
has been designed in conformity with the requirements of the Council directive for explosive atmospheres,
94/9/EC of March 1994 according to following standards.
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 ISO/IEC 80079-34 (2011)
Explosive atmospheres – Part 34: Application of quality systems for equipment manufacture.
IEC 61508-3(2001)
Functional safety of electrical/electronic/programmable electronic safety- related systems – Part 3:
Software requirements.
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.
In Vaasa, 16th of August, 2012
Vesa Laisi
President
11067.pdf
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4
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THERMISTOR FUNCTION (ATEX)
NXP CONTROL UNIT
OPT-AF board, slot B
Thermistor
+
Control board
Atex Safety
Function
-
SD1+
MICROCONTROLLER
Hardware
Safe Torque Off
1
SD1-
SD2+
Hardware
Safe Torque Off
2
SD2-
RO1/3
RO1/1
RO1/2
RO2/3
RO2/2
Relays only for operational use,
not part of theATEX certified thermistor
function
PWM control
POWER UNIT
=
3~
M
11068.emf
Figure 16. Thermistor function principle in NXP frequency converter with the OPT-AF board
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THERMISTOR FUNCTION (ATEX)
4.1
Technical data
STO inputs two
independent channels
+24V+
+24V+24V+
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Thermistor input
Thermistor Input: Thermistor
active > 4000 ohm. After being
active, the fault can be reset if
resistance is < 2000 ohm.
Jumper X10 for selecting
thermistor short
circuit supervision
SD1
SD2
+24VProgrammable
Relay
"NO/NC"
Programmable
Relay
"NO/NC"
Jumper wire X12
See Chapter 4.2.4.
11052.emf
Figure 17. The layout of the OPT-AF board
4.1.1
Functional description
The thermistor supervision circuit of the OPT-AF 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 acting directly
on the "STO" safety function of the NXP (See Figure 16) and is thus providing a reliable, software
and parameter independent way of preventing the energy supply to the motor.
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4.1.2
THERMISTOR FUNCTION (ATEX)
Hardware and connections
Table 6. OPT-AF I/O terminals
Terminal
1
SD1+
2
SD1-
3
SD2+
4
SD2-
21 RO1/normal closed
22 RO1/common
23 RO1/normal open
Parameter reference
on keypad and
NCDrive
DigIN:B.2
DigIN:B.3
Isolated STO input 1
+24 V +-20% 10... 15 mA
Virtual GND 1
Isolated STO input 2
+24 V +-20% 10... 15 mA
Virtual GND 2
DigOUT:B.1
Relay output 1 (NO/NC) *
Switching capacity 24 VDC/8 A
250 VAC/8 A
125 VDC/0.4 A
Min. switching load 5 V/10 mA
DigOUT:B.2
Relay output 2 (NO) *
Switching capacity 24 VDC/8 A
250 VAC/8 A
125 VDC/0.4 A
Min. switching load 5 V/10 mA
25 RO2/common
26 RO2/normal open
28 TI1+
29 TI1-
Technical information
DigIN:B.1
Thermistor input; Rtrip > 4.0 kΩ (PTC)
max voltage = 10 V
max current = 6,7 mA
The thermistor (PTC) is connected between the terminals 28(TI1+) and 29(TI1-) of the OPT-AF board.
The optocoupler isolates the thermistor inputs from the control board potential.
* If 230 VAC 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. Refer to standard EN 60204-1, section 7.2.9.
The overtemperature is detected by hardware on OPT-AF board. See temperature versus resistance curve as in the figure below.
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THERMISTOR FUNCTION (ATEX)
vacon • 38
11069.emf
Figure 18. Typical characteristics of a motor-protection sensor as specified
in DIN 44081/DIN 440
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4.2
THERMISTOR FUNCTION (ATEX)
Commissioning
Note: Installation, testing and service work on the OPT-AF board can be performed only by professional persons.
Note: It is not allowed to perform any repair work on the OPT-AF board.
4.2.1
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. It is recommended to use
a shielded control cable.
Maximum cable length without Maximum cable length with
short circuit monitoring
short circuit monitoring
X10: OFF
X10: ON
>= 1.5 sq mm
1500 meters
250 meters
Note: It is recommended to test the ATEX functionality using thermistor input on OPT-AF board periodically (typically once a year). For testing, the thermistor connection to the OPT-AF board is disconnected. The drive ready signal goes low (green LED on the keypad goes OFF). Check for the
corresponding warning or fault indication in the drive according to the parameter setting explained
in Chapter 4.2.2.
4.2.2
Parameter setting for ATEX function
In case of overtemperature, the drive modulation is disabled. The drive will not anymore feed energy to the motor thus preventing further overheating of the motor. See Figure 16.
When drive is connected to the main power and if the motor temperature is below overtemperature
limits (see Figure 18), the drive goes to ready state. The motor may start in presence of start command from a selected control place.
If the motor temperature is above the overtemperature limits (see Figure 18), fault /warning (F29)
thermistor is activated depending on the programming in the application.
The application programming for the thermistor fault is as follows e.g. in factory applications.
Code
Parameter
Default
ID
Note
P2.7.21
Response to
Thermistor Fault
2
732
0= No Response
1= Warning
2= Fault according to Stop Mode. *
3= Fault, stop by coasting.
* With OPT-AF board according to ATEX directive 94/9/EC (i.e jumper wire X12 not cut) , response
to thermistor fault = 2 is always same as response to thermistor fault =3, i.e. stop by coasting.
When the resistance of the thermistor(s) mounted in the motor goes above 4 kΩ due to motor overheating, the drive modulation is disabled within 20 ms. Fault F29 or warning A29 is generated in the
drive according to the above-mentioned programming.
According to the curve, when the temperature falls below 2 kΩ (see Figure 18), the thermistor function allows the drive to be enabled again.
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THERMISTOR FUNCTION (ATEX)
vacon • 40
The thermistor fault configuration cause following reactions:
•
•
•
Response to thermistor fault = No action. No warning/ fault is generated in case of overtemperature . The drive goes to run disable mode. The drive can be restarted when temperature
is normalized, by giving a valid start command.
Response to thermistor fault = Warning. A29 is generated in case of overtemperature. The
drive goes to run disable mode. The drive can be restarted when temperature is normalized
by giving a valid start command when the drive has returned to Ready state.
Response to thermistor fault = Fault. F29 is generated in case of overtemperature and the
drive goes to run disable mode. When the temperature is normalized, a reset command is
needed before the drive can be restarted. The drive returns to Ready state. The valid start
command is then needed to restart the drive.
Note: With OPT-AF board according to ATEX directive 94/9/EC (i.e jumper wire X12 not cut) all NXP
drives are programmed to accept only an edge sensitive start command for a valid start after a
thermistor fault . To start the motor operation, a new start command is required after the drive returns to ready state.
4.2.3
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, F8 system fault (subcode 31) is generated. When the
short circuit has been removed, the drive can be reset only after power recycle to the NXP control
board.
The short circuit monitoring can be enabled or disabled using the jumper X10 in ON or OFF position
respectively. The jumper is set in ON position by factory default.
Important: For the functionality of OPT-AF board according to ATEX directive 94/9/EC, it
must be checked that the jumper wire X12 is not damaged or cut. Also set the parameter Expander Boards/Slot B/ "Therm Trip (HW)" to "ON" (P.7.2.1.1).
4.2.4
Exceptional use of thermistor function on OPT-AF board
(similar to OPT-A3, not in compliance with ATEX directive 94/9/EC)
In systems where the drive detects the overtemperature of the motor through a thermistor input,
there might be a need of running down the whole system in a controlled way or continue running
the motor. In these cases the thermistor input must not cause an immediate stop of the drive. To
achieve this functionality, the following actions must be carried out:
•
•
•
Cut the jumper wire X12 on OPT-AF board.
Set the jumper X10 to OFF position (short circuit monitoring disabled).
Set the parameter Expander Boards/Slot B/ “Therm Trip (HW)” to “Off”.
WARNING: When the jumper wire X12 is cut, the OPT-AF board is not
more valid for using in an environment that requires a certified overheating protection device according to the ATEX directive 94/9/EC.
13006 emf
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THERMISTOR FUNCTION (ATEX)
4.2.5
OPT-AF board parameter
Code
Parameter
Default
Note
P7.2.1.1
Therm Trip
(HW)
“On”
Correct settings:
• "Jumper wire X12 not cut and this board parameter "On" (for ATEX)
• "Jumper wire X12 cut and this board parameter
"Off" (for no ATEX and similar to OPT-A3)
Refer 4.2.4
Wrong settings:
• "If jumper wire X12 is cut and this board parameter
is "On", thermistor trip will cause unresettable
System Fault 8, subcode 41.
• "If jumper wire X12 is not cut and this board
parameter is "Off", thermistor trip will cause unresettable System Fault 8, subcode 48.
P7.2.1.2
4
Start-Up Prev
“Fault”
To start the motor operation, after a thermistor fault, an
edge sensitive start command is required after the drive
returns to ready state.
a)
When OPT-AF board parameter "Start-Up Prev"
is "Fault", the drive will generate a "F26 StartUp Prev" fault if start command is on, when
returning to ready state after a thermistor fault
has been active. The drive can be started with
an edge sensitive start command after fault
reset.
b)
When OPT-AF board parameter "Start-Up Prev"
is "Warning", the drive will generate a "A26
Start-Up Prev" warning if start command is on,
when returning to ready state after a thermistor
fault has been active. The drive can be started
with an edge sensitive start command. No fault
reset is required in this case.
c)
When OPT-AF board parameter "Start-Up Prev"
is "No action", the drive will not generate any
indication. The drive can be started with an
edge sensitive start command. No fault reset is
required in this case.
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THERMISTOR FUNCTION (ATEX)
4.2.6
vacon • 42
Fault diagnosis of thermistor function
The table below shows the normal fault / warning, generated when thermistor input is active.
Table 7. Fault/ Warning indicating that the thermistor is active.
Fault
code
29
Fault/Warning Subcode
Thermistor
1
Possible cause
Thermistor input is activated (> 4 kΩ) on the OPTAF option board.
Correcting measures
The resistance of thermistor input must go below 2
kΩ to be able to restart the
drive.
The table below shows faults that may be generated from the software part that monitors the hardware related to the STO and thermistor function. If some of the faults mentioned in this table occur,
the fault may NOT be reset.
Table 8. Faults related to the STO & thermistor function
Fault
code
Fault
Subcode
Possible cause
8
System Fault
30
STO inputs are in different
state. This fault occurs
when the STO inputs are in
different state more than 5
seconds.
Correcting measures
-Check the S1 switch.
-Check the cabling to the
OPT-AF board.
-Single hardware problem
possible in either OPT-AF
board or NXP control
board.
8
System Fault
31
Thermistor short circuit
detected.
-Correct the cabling.
-Check the jumper for the
thermistor short circuit
supervision, if thermistor
function is not used, and the
thermistor input is short
circuited.
8
System Fault
32
OPT-AF board has been
removed.
-It is not allowed to remove
the OPT-AF board once it
has been reqognized by the
software. NOTE! There is
only one method to clear
this fault. By writing "OPTAF Removed" to "1" and
then back to "0" again. This
variable is found from the
"System Menu" "Security"
(6.5.5).
8
System Fault
33
OPT-AF board EEPROM
error (checksum, not
answering…).
-Change the OPT-AF board.
8
System Fault
34…36
OPT-AF supply voltage
hardware problem
detected.
-Change the OPT-AF board.
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THERMISTOR FUNCTION (ATEX)
Table 8. Faults related to the STO & thermistor function
4
Fault
code
Fault
Subcode
8
System Fault
37…40
Single hardware problem
detected in STO inputs.
-Change the OPT-AF board
or the NXP control board.
8
System Fault
41…43
Single hardware problem
detected in the thermistor
input.
-Change the OPT-AF board.
8
System Fault
44…46
Single hardware problem
-Change the OPT-AF board
detected in STO inputs or in or the NXP control board.
the thermistor input.
8
System Fault
47
OPT-AF board mounted in
old NXP control board.
8
System Fault
48
Parameter Expander
Correct the parameter
boards/SlotB/Therm
according to the jumper
Trip(HW) is set to OFF even settings.
if the jumper wire X12 is not
cut.
Possible cause
Correcting measures
-Change the NXP control
board to VB00561, rev. H or
newer.
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Find your nearest Vacon office
on the Internet at:
www.vacon.com
Manual authoring:
[email protected]
Vacon Plc.
Runsorintie 7
65380 Vaasa
Finland
Subject to change without prior notice
© 2012 Vacon Plc.
Document ID:
Rev. B