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Danfoss VLT MCB 150 Operating Instructions Manual

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MAKING MODERN LIVING POSSIBLE
Operating Instructions
Safety Option MCB 150/151
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Summary of Contents for Danfoss VLT MCB 150

  • Page 1 MAKING MODERN LIVING POSSIBLE Operating Instructions Safety Option MCB 150/151 www.danfoss.com/drives...

  • Page 3: Table Of Contents

    3.5.1 Operation and Requirements 3.5.2 Safety Functions 3.5.3 Safe Torque Off - STO 3.5.4 Safe Stop 1 - SS1 3.5.4.1 SS1 Delay 3.5.4.2 SS1 Delay with S-ramp Stop Profile 3.5.4.3 SS1 Ramp MG34W302 Danfoss A/S © Rev. 2014-02-11 All rights reserved.
  • Page 4 4.2.2 Encoder Wiring Examples 4.2.3 Proximity Switch 4.3 Application Examples 4.3.1 Connecting Safe Digital Inputs 5 Commissioning 5.1 Before Commissioning 5.1.1 Safety Guidelines 5.1.2 Commissioning Requirements 5.2 Initial Commissioning 5.2.1 Power-up/Self-test Danfoss A/S © Rev. 2014-02-11 All rights reserved. MG34W302...
  • Page 5 8.1 Fault Types and Messages 8.1.1 Messages 8.2 Warnings and Alarms 8.2.1 Safety Option Warning 8.2.2 Safety Option Reset Message 9 Technical Specifications 9.1 Consumption 9.2 Inputs 9.3 Outputs 9.4 Other Specifications MG34W302 Danfoss A/S © Rev. 2014-02-11 All rights reserved.
  • Page 6 Contents Operating Instructions 9.5 Safety Characteristic Data Index Danfoss A/S © Rev. 2014-02-11 All rights reserved. MG34W302...

  • Page 7: Introduction

    ® is a registered trademark. 1.2 Overview of Documentation Chapter 1 Introduction Explains the contents, structure and specific order of this manual. MG34W302 Danfoss A/S © Rev. 2014-02-11 All rights reserved.

  • Page 8: Abbreviations And Definitions

    MCT 10 Commisioning report 3 February 2012 Property of Danfoss A/S. Not to be handed over to, copied, or used by third party. Two - or three - dimensional reproduction of contents to be authorized by Danfoss A/S. Test Parameterize...
  • Page 9 A warning is not an error and does not cause a transition of the operating state. Table 1.1 Abbreviations and Definitions MG34W302 Danfoss A/S © Rev. 2014-02-11 All rights reserved.

  • Page 10: Legal Information And Safety

    AC mains input power. Installation, start This publication contains information proprietary to up, and maintenance should be performed by qualified Danfoss and is protected by Copyright laws of Denmark, personnel only. Failure to perform installation, start up, international treaties and most other countries. All...

  • Page 11: Safety Regulations

    The products may only be assembled, installed, programmed, commissioned, maintained and decommis- sioned by persons with proven skills. Persons with proven skills • are qualified electrical engineers, or persons who have received training from qualified electrical MG34W302 Danfoss A/S © Rev. 2014-02-11 All rights reserved.

  • Page 12: Functions And System Overview

    As speed monitor, the option is often used in combination example, this may cause the load of vertical axes to lower. Danfoss A/S © Rev. 2014-02-11 All rights reserved. MG34W302...

  • Page 13: Safety Certification

    EN IEC 61508 and EN IEC 62061, include a rating of the If using another validation method for the performance system's ability to perform its safety functions. level, use the characteristic safety values specified. MG34W302 Danfoss A/S © Rev. 2014-02-11 All rights reserved.

  • Page 14: Activation Of Safety Functions

    C Actual ramp stop function Illustration 3.3 2 Safe Stop 1 Safety Functions Active Illustration 3.3 shows the result of activating first a Safe Stop 1 function with a given ramp and afterwards Danfoss A/S © Rev. 2014-02-11 All rights reserved. MG34W302...

  • Page 15: Functional Proof Tests

    Table 8.2 in accordance with IEC 61800-5-2, regarding safe motion • Supply voltage monitoring. Internally supplied by the frequency converter. 24 V DC output for safety sensors and encoder available. MG34W302 Danfoss A/S © Rev. 2014-02-11 All rights reserved.

  • Page 16: Front View

    If access to the machine coasting down involves a hazard (results of the hazard and risk analysis), Prevents exceeding a defined speed take protective measures to avoid the hazard. value Danfoss A/S © Rev. 2014-02-11 All rights reserved. MG34W302...

  • Page 17: Safe Torque Off - Sto

    Select SS1 Delay to activate Safe Stop 1 function while a converter output stage. Thus, it prevents the frequency parameterised safety delay timer expires. MG34W302 Danfoss A/S © Rev. 2014-02-11 All rights reserved.

  • Page 18: Ss1 Delay With S-Ramp Stop Profile

    It coasts after the time delay regardless of the frequency converter speed. Define an S-ramp configuration, which achieves zero speed within the delay. Danfoss A/S © Rev. 2014-02-11 All rights reserved. MG34W302...

  • Page 19: Ss1 Ramp

    This action prevents the frequency immediately after motion is detected as stopped rather converter from continuing to run or even accelerating in than waiting until a specific time has elapsed. the event of an error. MG34W302 Danfoss A/S © Rev. 2014-02-11 All rights reserved.

  • Page 20: Ss1 Ramp Time

    There are 2 types of Safely Limited and a tolerable speed (Delta V). Speed • SLS without ramp: Monitors the motor speed and, depending on the setting of 42-52 Fail Safe Danfoss A/S © Rev. 2014-02-11 All rights reserved. MG34W302...

  • Page 21: Sls Without Ramp

    A suggested value from MCT 10 Set-up Software calculates a value for which Danfoss guarantees functionality. This value is called delta speed limit and is added to the selected speed limit and suggested as value in 42-50 Cut Off Speed.

  • Page 22: Sls With Ramp

    Speed fault occurs and the safety option initiates the configured Safe Stop type selected in 42-52 Fail Safe Reaction. The ramping begins at the absolute value of the actual speed. If the actual speed is already below the Safely Danfoss A/S © Rev. 2014-02-11 All rights reserved. MG34W302...

  • Page 23: Inputs And Output

    If manual reset is configured, wire the DI2A At the same time, the option output S37 goes low. reset input terminal to a 24 V DC via an NO switch. MG34W302 Danfoss A/S © Rev. 2014-02-11 All rights reserved.

  • Page 24: Output

    Parameterise the discrepancy time of the switching a reset, the safety option can be switched on again. This elements connected to the digital inputs. The default value deactivates active safety functions or errors. is 10 ms. Danfoss A/S © Rev. 2014-02-11 All rights reserved. MG34W302...

  • Page 25: Stable Signal Time From Safe Outputs

    3.6.10 Safety Parameter Settings Factory setting for both digital inputs is Safe Torque Off, meaning that the Safe Output S37 is in low state. MG34W302 Danfoss A/S © Rev. 2014-02-11 All rights reserved.

  • Page 26: Encoder Interface

    Internal errors always result in a fault, requiring a power cycle of the frequency converter to reset the failure. Alternatively, use 42-90 Restart Safe Option to restart the safety option after internal failure without power cycling the frequency converter. Danfoss A/S © Rev. 2014-02-11 All rights reserved. MG34W302...

  • Page 27: Installation

    Remove the LCP, the terminal cover, and the LCP • ® AutomationDrive FC 302, power sizes from frame from the frequency converter. 0.37 kW to 75 kW, from SW Version 6.64 MG34W302 Danfoss A/S © Rev. 2014-02-11 All rights reserved.
  • Page 28 Fit the extended LCP frame and terminal cover. relieve the cable by the enclosed cable strips. Follow the guidelines in chapter 4.1.4 General Wiring Guidelines. 11 12 Illustration 4.4 Connecting Control Wiring Danfoss A/S © Rev. 2014-02-11 All rights reserved. MG34W302...

  • Page 29: General Wiring Guidelines

    All signals to safety option must be PELV supplied and comply with EN IEC 60204. • Route sensitive control cables - such as encoder and active safety component cables - without any MG34W302 Danfoss A/S © Rev. 2014-02-11 All rights reserved.

  • Page 30: Connector Pin Assignment

    STO enable Table 4.1 Connector Pin Assignment, MCB 150 MCB 150 Option B 130B3280 Safe Option SW. ver. xx. xx TTL Enc. interface LED: 9 10 Y30/ Illustration 4.5 Nameplate MCB 150 Danfoss A/S © Rev. 2014-02-11 All rights reserved. MG34W302...
  • Page 31 STO enable Table 4.2 Connector Pin Assignment, MCB 151 MCB 151 Option B 130B3290 Safe Option SW. ver. xx. xx HTL Enc. interface LED: 9 10 Y31/ Illustration 4.6 Nameplate MCB 151 MG34W302 Danfoss A/S © Rev. 2014-02-11 All rights reserved.

  • Page 32: Encoder

    (ppr) is 2 on the motor shaft while considering the gear ratio. 4.2.2 Encoder Wiring Examples Illustration 4.7 and Illustration 4.8 show examples of how to connect encoder power and encoder signals. Danfoss A/S © Rev. 2014-02-11 All rights reserved. MG34W302...

  • Page 33: Application Examples

    OSSD 2 24 V DC FC 302 Illustration 4.12 Connecting an Electronic Sensor, e.g. Safety Light Curtain Measuring plate Proximity switch Disc (non conducting material) Illustration 4.10 Gear Wheel for Proximity Switch MG34W302 Danfoss A/S © Rev. 2014-02-11 All rights reserved.
  • Page 34 All equipment used must be suitable for the selected category/PL or SIL. Up to 3 frequency converters may be connected in a daisy chain. Total cable length must not exceed 30 m. Danfoss A/S © Rev. 2014-02-11 All rights reserved. MG34W302...

  • Page 35: Commissioning

    Safe Torque Off is option. triggered. The safety-related output S37 on the option is switched off. Configure the safety option in the MCT 10 with Safe Plug-in. Ensure only to configure safety MG34W302 Danfoss A/S © Rev. 2014-02-11 All rights reserved.

  • Page 36: Initial Commissioning

    (default) or [1] Counter clockwise. Set 42-14 Feedback Type to [0] With direction info or [1] Without direction info. Select [1] Without direction info if proximity switch sensor is used for speed detection. Danfoss A/S © Rev. 2014-02-11 All rights reserved. MG34W302...

  • Page 37: Commissioning Test

    Stop of the frequency converter are described in the frequency converter manuals. The tests for the optional safety functions are described in the commissioning report generated by the MCT 10 Safe Plug-in. The commissioning test must be performed MG34W302 Danfoss A/S © Rev. 2014-02-11 All rights reserved.

  • Page 38: General Parameter Set-Up

    Further information on configuration and setting parameters for the safety functions is available in the online help for the MCT 10 Safe Plug-in and in the MCT 10 Set-up Software Operating Instructions. Danfoss A/S © Rev. 2014-02-11 All rights reserved. MG34W302...

  • Page 39: Password Forgotten

    The frequency converter specific alarms are also reset. DI_1_offline_warning DI_2_offline_warning If 42-31 Reset Source is set to [1] Drive Safe Reset, [3] Safe Error code Option Reset must be configured in 8-14 Configurable Error code Control Word CTW. MG34W302 Danfoss A/S © Rev. 2014-02-11 All rights reserved.
  • Page 40 Bit 15 = "0", No Safe function pending Bit 15 = "1", Safe function pending Bit 16, General Reset Bit 16 = "0", No change in state Bit 16 = "1", General Reset is done Danfoss A/S © Rev. 2014-02-11 All rights reserved. MG34W302...
  • Page 41 Pending Bit 04, Blank Initial Status Bit 04 = “0” Safety option is configured Bit 04 – “1” Safety option is in blank initial state Bit 05-31 Reserved for future use MG34W302 Danfoss A/S © Rev. 2014-02-11 All rights reserved.

  • Page 42: Parameter List

    6.3 Parameter List All parameters except 42-90 Restart Safe Option are read only. ® Refer to VLT AutomationDrive FC 302 Programming Guide for general information about usage of conversion index and data type. Danfoss A/S © Rev. 2014-02-11 All rights reserved. MG34W302...
  • Page 43 8760 h Time period where u_int16 Timer the option is allowed to be below 120 RPM when SLS is active before STO is activated. 42-19 Zero Speed Fixed 120 RPM u_int16 Limit MG34W302 Danfoss A/S © Rev. 2014-02-11 All rights reserved.
  • Page 44 Reset, only the safety option is reset. 42-33 Parameter Set Visible String, SafeSet1 Name of the safe Name length: 8 parameter Set (must be 8 characters to avoid a bad customi- sation data error). Danfoss A/S © Rev. 2014-02-11 All rights reserved. MG34W302...
  • Page 45 (42-42 Delay Time) where the deceleration torque decreases. The larger the percentage value, the greater the jerk compensation achieved, and thus the lower the torque jerks in the application. MG34W302 Danfoss A/S © Rev. 2014-02-11 All rights reserved.
  • Page 46 Shows information Info function is active about the safety option. Can be used on LCP. NOTICE Can only be selected in 0-23 Display Line 2 Large and 0-24 Display Line 3 Large. Danfoss A/S © Rev. 2014-02-11 All rights reserved. MG34W302...
  • Page 47 [1] Yes option after internal failure without power cycling the frequency converter. Table 6.3 Safety Option Parameters ® Refer to VLT AutomationDrive FC 301/FC 302 Operating Instructions for a comprehensive parameter list. MG34W302 Danfoss A/S © Rev. 2014-02-11 All rights reserved.

  • Page 48: Service And Repair

    Adapt Only Danfoss is authorised to make repair to the safety the configuration in the MCT 10 Set-up Software. option. A defect option must be shipped back to Danfoss.

  • Page 49: Copying Safe Parameter Set-Up

    Verify that the correct safety parameter file is transferred to the safety option. Perform a commissioning test, see chapter 5.2.5 Commis- sioning Test. 7.3.3 Copying Safe Parameter Set-up To copy the safe parameter set-up to another frequency converter MG34W302 Danfoss A/S © Rev. 2014-02-11 All rights reserved.
  • Page 50 ([1] Enabled) 0 RPM None 1(1) If the entered password is wrong, this overlay message is shown for some seconds. Then the password Password rejected can be entered again. ([1] Enabled) Danfoss A/S © Rev. 2014-02-11 All rights reserved. MG34W302...
  • Page 51 If selecting [SO:…], the customization of the safety option is completed and a reset is required to SO Custom. completed SO RESET required! finalize this procedure. !Safe Stop [W68] O Remote SO Req.RESET MG34W302 Danfoss A/S © Rev. 2014-02-11 All rights reserved.
  • Page 52 Press [Cancel] to abort the customisation of the safety option. A reset is required to finalise this SO RESET required! procedure. !Safe Stop [W68] O Remote SO Req.RESET Table 7.2 Mismatch between Safety Parameters in the safety Option and the Frequency Converter Danfoss A/S © Rev. 2014-02-11 All rights reserved. MG34W302...

  • Page 53: Commissioning Test

    Secure the site in accordance with the regulations commissioning test of the safety option to verify and (barrier, warning signs etc.). The system may only document the correct selection of the safety option parameter values. The system integrator/machine MG34W302 Danfoss A/S © Rev. 2014-02-11 All rights reserved.
  • Page 54 Do NOT release the system unless it has successfully passed all individual steps of the test. Restart the frequency converter and check that the motor runs normally. Danfoss A/S © Rev. 2014-02-11 All rights reserved. MG34W302...

  • Page 55: Safety Functions Of The Frequency Converter

    10. Ensure that the Safe Torque Off function is safe and accepted to operate. 11. Document and sign the commissioning test report. Table 7.3 Commissioning Test Report, Safe Torque Off MG34W302 Danfoss A/S © Rev. 2014-02-11 All rights reserved.
  • Page 56 10. Ensure that the Safe Stop 1 function is ready to operate. 11. Document and sign the commissioning test report. Table 7.4 Commissioning Test Report, Safe Stop 1 Time Based Danfoss A/S © Rev. 2014-02-11 All rights reserved. MG34W302...
  • Page 57 9. Restart the frequency converter and check that the motor runs normally. 10. Ensure that the Safe Stop 1 function is ready to operate. 11. Document and sign the commissioning test report. Table 7.5 Commissioning Test Report, Safe Stop 1 Delay MG34W302 Danfoss A/S © Rev. 2014-02-11 All rights reserved.
  • Page 58 10. Ensure that the Safe Stop 1 function is ready to operate. 11. Document and sign the commissioning test report. Table 7.6 Commissioning Test Report, Safe Stop 1 Ramp Based Danfoss A/S © Rev. 2014-02-11 All rights reserved. MG34W302...
  • Page 59 Increase reference above SLS limit Make sure that SLS limit will not be exceeded 11. Document and sign the commissioning test report. Table 7.7 Commissioning Test Report, Safely Limited Speed without Ramp MG34W302 Danfoss A/S © Rev. 2014-02-11 All rights reserved.
  • Page 60 16. Ensure that the Safely Limited Speed function is ready to operate. 17. Document and sign the commissioning test report. Table 7.8 Commissioning Test Report, Safely Limited Speed with Ramp Tester/Approver Date: Signature: Danfoss A/S © Rev. 2014-02-11 All rights reserved. MG34W302...

  • Page 61: Disposal

    7.5 Disposal Equipment containing electrical components may not be disposed of together with domestic waste. It must be separately collected with electrical and electronic waste according to local and currently valid legislation. MG34W302 Danfoss A/S © Rev. 2014-02-11 All rights reserved.

  • Page 62: Warnings And Alarms

    • LCP text or info via bus display the status of the safety functions (e.g. SS1a). The following are displayed in online mode in the MCT 10 Set-up Software Danfoss A/S © Rev. 2014-02-11 All rights reserved. MG34W302...

  • Page 63: Warnings And Alarms

    • Otherwise increase filter (42-15 Feedback 42-45 Delta V. Filter). • Load change takes place during ramping. Int fail Speed See 68 See 68 Red constant limit SS1b Ramp: Reaction MG34W302 Danfoss A/S © Rev. 2014-02-11 All rights reserved.
  • Page 64 Danfoss • Internal failure First, power cycle the Red constant MCB 150/151 frequency converter or restart the safety option by 42-90 Restart Safe Option. • If the problem persists, contact Danfoss Danfoss A/S © Rev. 2014-02-11 All rights reserved. MG34W302...
  • Page 65 Configure the safety Red constant data CRC option does not match option with MCT 10 mismatch: the stored CRC value on safe plug-in or by CRC Reaction STO the frequency converter. select/LCP copy MG34W302 Danfoss A/S © Rev. 2014-02-11 All rights reserved.
  • Page 66 • If the problem persists, contact Danfoss • Internal failure First, power cycle Red constant safety option the frequency converter. • If the problem persists, contact Danfoss Danfoss A/S © Rev. 2014-02-11 All rights reserved. MG34W302...
  • Page 67 • If the problem persists, contact Danfoss • Internal failure First, power cycle Red constant safety option the frequency converter. • If the problem persists, contact Danfoss MG34W302 Danfoss A/S © Rev. 2014-02-11 All rights reserved.
  • Page 68 42-21 Type ms, off 500 parameter is set • Status depends on Sensor is broken. correctly or the safety function state connected sensor assigned to DI2 is installed according to specification Danfoss A/S © Rev. 2014-02-11 All rights reserved. MG34W302...
  • Page 69 500 Ext Fail See 114 See 114 Status depends on Red constant Red flashing, DI2 :Reaction Safety function state cycle (on 500 SS1a assigned to DI1 ms, off 500 MG34W302 Danfoss A/S © Rev. 2014-02-11 All rights reserved.

  • Page 70: Safety Option Warning

    The safety option uses 'Safe Option RESET' as a ‘Restart and Failure Acknowledgement‘ NOTICE At any possible failure or warning indicated from the safety option, the LCP displays Warning ‘!Safe Option Failure [W252]’ at the least. Danfoss A/S © Rev. 2014-02-11 All rights reserved. MG34W302...
  • Page 71 Acknowledge signal’, which is SafeOpt. initialised always required after a PUST and when a safety function !Safe Stop [W68] gets released and is configured to be confirmed that the motor is able to run. MG34W302 Danfoss A/S © Rev. 2014-02-11 All rights reserved.

  • Page 72: Technical Specifications

    Maximum frequency 110 kHz Short circuit-proof < 100 m (Tested with screened cable - Heidenhain AWM Style 20963 80°C 30V E63216, 100 m screened Cable length motor cable, no load on motor) Danfoss A/S © Rev. 2014-02-11 All rights reserved. MG34W302...

  • Page 73: Outputs

    Start-up reset time Response time ≤ 2 ms Input to output response time ≤ 7 ms Emergency stop until beginning of SS1/SLS ≤ 3 ms (@activated output) Cross fault detection time MG34W302 Danfoss A/S © Rev. 2014-02-11 All rights reserved.
  • Page 74 Table 9.1 Safety Characteristic Data The safety-related characteristic data are valid for all safety functions. All units used within a safety function must be considered when calculating the safety characteristic data. Danfoss A/S © Rev. 2014-02-11 All rights reserved. MG34W302...
  • Page 75 USB....................33, 36, 47 Option change..................47 Warnings and alarms................60 Password....................47 Warranty....................8, 46 PFD definition..................13 PFH definition..................13 PNP proximity switch................31 PNP proximity Switch..............14, 24 Priority...................... 12 MG34W302 Danfoss A/S © Rev. 2014-02-11 All rights reserved.
  • Page 76 Danfoss can accept no responsibility for possible errors in catalogues, brochures and other printed material. Danfoss reserves the right to alter its products without notice. This also applies to products already on order provided that such alterations can be made without subsequential changes being necessary in specifications already agreed. All trademarks in this material are property of the respective companies.

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