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Danfoss iC7 Series Operating Manual

Danfoss iC7 Series Operating Manual

Automation functional safety
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Operating Guide
iC7-Automation Functional Safety
Frequency Converters, 1.3–1260 A
drives.danfoss.com |

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Summary of Contents for Danfoss iC7 Series

  • Page 1 Operating Guide iC7-Automation Functional Safety Frequency Converters, 1.3–1260 A drives.danfoss.com |...

  • Page 3: Table Of Contents

    Commissioning Test for STO Applications in Automatic Restart Mode 3.3.2.3 Operation and Maintenance 3.4.1 Functional Tests Conducting Functional Tests 3.4.1.1 Functional Test Using STO Feedback Signal 3.4.1.2 Functional Test without Using STO Feedback Signal 3.4.1.3 Danfoss A/S © 2024.08 AQ319741840653en-000401 / 136R0268 |...
  • Page 4 PROFIsafe System 4.5.3 PROFIsafe Frame 4.5.4 Parameterization for PROFIsafe PROFIsafe Watchdog Time 4.5.5 4.5.6 PROFIsafe Safety Function Response Time (SFRT) 4.5.7 PROFIdrive on PROFIsafe PROFIsafe Control Word 4.5.8 4.5.9 PROFIsafe Status Word Installation | Danfoss A/S © 2024.08 AQ319741840653en-000401 / 136R0268...
  • Page 5 Instances of the STO Feedback Signal 4.10.2 4.10.3 Safety Function Fault Recovery 4.10.4 Event List 4.11 Specifications 4.11.1 Functional Safety Standards and Performance 4.11.2 Technical Data Operating Conditions 4.11.3 4.11.4 Cable Specifications Danfoss A/S © 2024.08 AQ319741840653en-000401 / 136R0268 |...
  • Page 6 Operating Guide | iC7-Automation Functional Safety Contents | Danfoss A/S © 2024.08 AQ319741840653en-000401 / 136R0268...

  • Page 7: Introduction

    Installation guides, which cover the mechanical and electrical installation of drives, power converters, or functional extension options. Design guides, which provide technical information to understand the capabilities of the iC7 series drives or power converters for integration into motor control and monitoring systems.

  • Page 8: Trademarks

    Minor updates. The information in this version is valid for iC7-Automation frequency converters up to 106 A. AQ319741840653, version 0101 First release. The information in this version is valid for iC7-Automation frequency con- verters up to 43 A. | Danfoss A/S © 2024.08 AQ319741840653en-000401 / 136R0268...

  • Page 9: Safety

    Emergency-Off function as defined by IEC 60204-1:2018. Using the STO function to implement Emergency-Off may lead to death or personal injury. Emergency-Off requires measures of electrical isolation, for example, by switching off mains via an extra contactor. Danfoss A/S © 2024.08 AQ319741840653en-000401 / 136R0268 |...

  • Page 10: Functional Safety For Frequency Converters With Sto, Not Upgradable (+Bef1)

    Only 1 input energized Failure in demand or Activated Deactivated "STO – Fault [channel due to internal fault name]" 1) Regular STO demand: Can be either fault or warning depending on restart settings. | Danfoss A/S © 2024.08 AQ319741840653en-000401 / 136R0268...

  • Page 11: System Configuration Security

      CAUTION The default restart behavior is set to Manual. Before switching to Automatic, ensure that requirements of EN ISO 12100:2011 paragraph 6.3.3.2.5 are fulfilled. Danfoss A/S © 2024.08 AQ319741840653en-000401 / 136R0268 |...

  • Page 12: Sto Properties

    Asynchronous input tolerance: The input signals at the STO terminals are not always synchronous. If the discrepancy between the 2 signals is longer than 500 ms, the drive indicates an STO fault as described in Table 4. This feature does not delay the activation of the STO function. | Danfoss A/S © 2024.08 AQ319741840653en-000401 / 136R0268...

  • Page 13: Sto Feedback

    Figure 3: STO Feedback Example for iC7 Frequency Converters It can also be used as a digital output for providing a status signal. In this case, the load could be a digital input of a PLC. Danfoss A/S © 2024.08 AQ319741840653en-000401 / 136R0268 |...

  • Page 14: Installation

      NOTICE If multi-stranded wires are used in the installation, ferrules or other suitable means must be used to prevent a single core from short-circuiting with adjacent pins. | Danfoss A/S © 2024.08 AQ319741840653en-000401 / 136R0268...
  • Page 15 6, or use the STO jumper clips from the accessory bag and mount them on X31 and X32. This ensures that both STO inputs are energized with 24 V DC for enabling normal operation. Danfoss A/S © 2024.08 AQ319741840653en-000401 / 136R0268 |...

  • Page 16: Connection Examples

    +24 V 43 S.INB+ 44 S.FB+ Safety Actuator 45 GND 46 S.INA– 47 S.INB– 48 S.FB– Figure 7: STO Connection Example for Using the Same Polarities (Channel A and Channel B = 24 V) | Danfoss A/S © 2024.08 AQ319741840653en-000401 / 136R0268...

  • Page 17: Commissioning

    A successful commissioning test is required after the initial installation, and after each change to the installation or application involving functional safety. If the commissioning test fails, safe operation cannot be guaranteed. Danfoss A/S © 2024.08 AQ319741840653en-000401 / 136R0268 |...

  • Page 18: Commissioning Test For Sto Applications In Manual Restart Mode

    If a control panel is mounted, check if STO activated is shown on the control panel. If the control panel is not mounted, check if STO activated is listed in the event log. | Danfoss A/S © 2024.08 AQ319741840653en-000401 / 136R0268...

  • Page 19: Operation And Maintenance

    It may take a long time for the motor to stop. ☐ Verify that the STO Feedback output signals an active STO. The output signals a full STO only when both channels are invoked. Danfoss A/S © 2024.08 AQ319741840653en-000401 / 136R0268 |...

  • Page 20: Functional Test Without Using Sto Feedback Signal

    If the control panel is not mounted, check if STO – Fault Ch B is listed in the event log. ☐ Give a start command to verify that the STO function blocks the drive's operation. The motor must not start. ☐ Reapply 24 V DC to STO inputs. | Danfoss A/S © 2024.08 AQ319741840653en-000401 / 136R0268...

  • Page 21: Diagnostic Tests

    Verify that the STO Feedback output does not signal an active STO. (The output signals a full STO only when both channels are invoked.) ☐ Give a start command to verify that the STO function blocks the drive's operation. The motor must not start Danfoss A/S © 2024.08 AQ319741840653en-000401 / 136R0268 |...

  • Page 22: Specifications

    EMC Directive (2014/30/EU) EN IEC 61800-3:2018 – second environ- ment EN IEC 61326-3-1:2017 Low Voltage Directive (2014/35/EU) EN IEC 61800-5-1:2017 Safety standards Safety of Machinery EN ISO 13849-1:2015, IEC 60204-1:2018 Functional Safety IEC 61508-1:2010, IEC 61508-2:2010, EN IEC 61800-5-2:2017 Safety function EN IEC 61800-5-2:2017 Safe Torque Off (STO) IEC 60204-1:2018 Stop Category 0 | Danfoss A/S © 2024.08 AQ319741840653en-000401 / 136R0268...

  • Page 23: Technical Data

    Table 12: 24 V Digital Input for STO Input Function Data Input type Single-ended/floating Logic Voltage level 0–24 V DC Voltage level, logic 0 PNP <5 V Voltage level, logic 1 PNP >11 V Danfoss A/S © 2024.08 AQ319741840653en-000401 / 136R0268 |...

  • Page 24: Operating Conditions

    Table 15: Operating Conditions for Functional Safety Function Data Operating temperature According to the AC drive specifications. Storage temperature -40 °C...+70 °C (-40 °F...+158 °F) Air humidity According to the AC drive specifications (non-condensing). | Danfoss A/S © 2024.08 AQ319741840653en-000401 / 136R0268...

  • Page 25: Cable Specifications

    For PD2 condensing environments, the product must be installed in IP54/NEMA 12 cabi- net as per EN IEC 60529 AMD 2:2013, or equivalent. Check the operating conditions for each drive from the product-specific design guide or operating guide. Latest versions of Danfoss product guides are available for download at https://www.danfoss.com/en/service-and-support/documentation/.

  • Page 26: Functional Safety For Frequency Converters, Upgradable (+Bef2)

    Select and apply the components in the safety control system appropriately to achieve the required level of operational safety. Before integrating and using STO in an installation, carry out a thorough risk analysis on the installation to determine whether the STO functionality and safety levels are appropriate and sufficient. | Danfoss A/S © 2024.08 AQ319741840653en-000401 / 136R0268...

  • Page 27: Sto Activation

    Nonsafe Acknowledge required: Acknowledgment through a selected non-safe input or fieldbus is required. Safe Acknowledge required: Acknowledgment through a selected safe input or safe fieldbus is required. If the problem persists and the device stays in error mode, contact Danfoss. IMPORTANT:  ...

  • Page 28: Safety Input Properties

    2 signals is longer than 500 ms, the drive indicates an IO failure as described in 4.10.2 Instances of the STO Feedback Signal. This feature does not delay the activation of the safety function. | Danfoss A/S © 2024.08 AQ319741840653en-000401 / 136R0268...

  • Page 29: Sto Feedback

    Software update De-energized During software update, the state of the safe output is not reli- able. STO output is de-energized. Danfoss A/S © 2024.08 AQ319741840653en-000401 / 136R0268 |...
  • Page 30 –STO feedback Load Figure 12: STO Feedback Example for iC7 Frequency Converters The STO feedback works similar to a contactor which is closed as soon as both STO input channels are de-energized. | Danfoss A/S © 2024.08 AQ319741840653en-000401 / 136R0268...

  • Page 31: Parameters For Safety Functions

    Acknowledge input for IO fail- Not selected Not selected Specifies the safe digital input, ures (B) which can be associated to the Safe Input (X31/X32) acknowledgment of the IO fail- ures. Danfoss A/S © 2024.08 AQ319741840653en-000401 / 136R0268 |...

  • Page 32: Failure Configuration

    First instance of SS1 1) Parameters are identified with letters in the Safety configuration section in MyDrive® Insight. The letter is given in parentheses after the parameter name for each parameter in this table. | Danfoss A/S © 2024.08 AQ319741840653en-000401 / 136R0268...

  • Page 33: Safe Fieldbus

    Safe Acknowledge required Digital input assignment for Not selected Not selected Specifies the safe digital input, STO restart acknowledge (C) which can be associated to the Safe Input (X31/X32) STO restart acknowledgment. Danfoss A/S © 2024.08 AQ319741840653en-000401 / 136R0268 |...

  • Page 34: Safe Stop 1 Time-Controlled (Ss1-T)

    ) Maximum time (B) 2–3600000 ms 2 ms The maximum time of the stop procedure. Delay before monitoring (C) 1–60000 ms 1 ms The time to ignore the decel- eration after the activation of SS1. | Danfoss A/S © 2024.08 AQ319741840653en-000401 / 136R0268...
  • Page 35 Using SS1 delay may result in the motor still spinning when Safe Torque Off is activated. The risk analysis for the machine must indicate that this behavior can be tolerated. An interlock may be required. Danfoss A/S © 2024.08 AQ319741840653en-000401 / 136R0268 |...

  • Page 36: Saving To Device

    PROFIsafe is an additional safety protocol on top of a standard transmission system (PROFINET/PROFIBUS). PROFIsafe uses several technologies to ensure the validity and status of the fieldbus communication, making it reliable to use with safety devices. These measures include: Consecutive numbering. | Danfoss A/S © 2024.08 AQ319741840653en-000401 / 136R0268...

  • Page 37: Profisafe System

    To indicate, monitor, and set the safety status of the F-device, see the status and control bytes descriptions in Table 23 Table For more details, refer to PROFIsafe – Profile for Safety Technology on PROFIBUS DP and PROFINET IO Technical Specification. Danfoss A/S © 2024.08 AQ319741840653en-000401 / 136R0268 |...

  • Page 38: Parameterization For Profisafe

    Table 25: Settings in the Safety PLC Value Description F source address PROFIsafe address of PLC. F destination address The value must be the same as the F destination address on the AC drive. | Danfoss A/S © 2024.08 AQ319741840653en-000401 / 136R0268...

  • Page 39: Profisafe Watchdog Time

    PROFIsafe. The values in the following table are defined in the fieldbus GSD description file, which is provided for the gateway chip in the drive by Danfoss, and must not be modified.

  • Page 40: Profisafe Safety Function Response Time (Sfrt)

    Adding the worst case delay times to the components of the safety system gives the total worst case delay time, as stated in Table Table 29: Time Parameters Device Worst case delay time Watchdog time The complete AC drive system 120 ms Recommended 250 ms or more | Danfoss A/S © 2024.08 AQ319741840653en-000401 / 136R0268...

  • Page 41: Profidrive On Profisafe

    “active”. SS1_INSTANCE_1 If SS1 is triggered by safe DI, this bit also indicates “ac- tive”. 2–6 Not supported Bits that are not supported are set to 0. INTERNAL_EVENT – Danfoss A/S © 2024.08 AQ319741840653en-000401 / 136R0268 |...

  • Page 42: Installation

    16 for the location of the terminals.   NOTICE If multi-stranded wires are used in the installation, ferrules or other suitable means must be used to prevent a single core from short-circuiting with adjacent pins. | Danfoss A/S © 2024.08 AQ319741840653en-000401 / 136R0268...
  • Page 43 If the STO safety function is not needed: – Wire the terminal block as shown in Figure 17, or use the STO jumper clips from the accessory bag, and mount them on X31 Danfoss A/S © 2024.08 AQ319741840653en-000401 / 136R0268 |...

  • Page 44: Connection Examples

    +24 V 43 S.INB+ 44 S.FB+ Safety Actuator 45 GND 46 S.INA– 47 S.INB– 48 S.FB– Figure 18: STO Connection Example for Using the Same Polarities (Channel A and Channel B = 24 V) | Danfoss A/S © 2024.08 AQ319741840653en-000401 / 136R0268...

  • Page 45: Configuration Tools

    Use these instructions to connect the drive or several drives to a PC with an RJ45 cable. Connect an RJ45 cable to the PC. To connect several drives at the same time, use an Ethernet switch between the PC and the control unit. Danfoss A/S © 2024.08 AQ319741840653en-000401 / 136R0268 |...

  • Page 46: Mydrive® Insight

    4.7.4 Installing MyDrive® Insight 4.7.4.1 To install the tool, go to https://suite.mydrive.danfoss.com/content/tools. Install MyDrive® Insight. For more information on how to use the tool, see the online help in MyDrive® Insight. Use MyDrive® Insight to connect the drive to a PC.

  • Page 47: Updating Software

    Check that the device is in normal state and there are no errors. Check the software package version and compatibility, and retry the software update. If the problem persists and the device stays in error mode, contact Danfoss. Danfoss A/S © 2024.08...

  • Page 48: Commissioning Safety

    The system integrator/machine manufacturer hereby proves to have tested the effectiveness and the completeness of the safety functions used. The commissioning tests must be performed based on the risk analysis. All applicable standards and regulations must be adhered to. | Danfoss A/S © 2024.08 AQ319741840653en-000401 / 136R0268...

  • Page 49: Commissioning Test For Safety Function Sto

    If STO feedback is used, check the state of the STO feedback to verify that STO is activated. See Figure ☐ Verify that the motor coasts. It may take a long time for the motor to stop. Danfoss A/S © 2024.08 AQ319741840653en-000401 / 136R0268 |...

  • Page 50: Commissioning Test For Safety Function Safe Stop 1 Time-Controlled (Ss1-T)

    If automatic acknowledgment is not used: Set an acknowledgment (for example, with an acknowledg- ment button). The acknowledgment is configured in safety parameters. ☐ Ensure that the motor becomes operational and runs within the original speed range. | Danfoss A/S © 2024.08 AQ319741840653en-000401 / 136R0268...

  • Page 51: Validating And Generating A Commissioning Report

    If a component failure occurs in functions related to safety, the drive must be replaced by authorized personnel. It is not allowed to modify or repair the safety circuitry in any way. Danfoss A/S © 2024.08 AQ319741840653en-000401 / 136R0268 |...

  • Page 52: Diagnostics

    After the faulty drive has been replaced, it must be commissioned. Refer to the product-specific guides for details and instructions for commissioning the drive, and also follow the procedures described in chapter Commissioning. | Danfoss A/S © 2024.08 AQ319741840653en-000401 / 136R0268...

  • Page 53: Troubleshooting

    The acknowledgment is configured in safety parameters. If a failure in the safety system or a safety function prevents fault recovery, contact a local Danfoss representative. Provide the commissioning report of the safety parameter configuration. For more information, see the MyDrive® Insight documentation.

  • Page 54: Event List

    4608 Internal failure An internal failure was detected in the Restart the system. safety system. If the problem persists, contact Danfoss customer support. 4609 IO failure detected An IO failure was detected in the safety Check the safety IO circuit connections. If system.
  • Page 55 The value of a parameter is out of the al- Make sure that the value of the given vari- lowed range. The variable ID is provided able is set in the allowed range. as detail. Danfoss A/S © 2024.08 AQ319741840653en-000401 / 136R0268 |...

  • Page 56: Specifications

    Check that the drive system does not have any unrelated special conditions, such as software update or drive commissioning, active. Try restarting the drive system. If the problem persists, contact Danfoss customer support. 4730 Information Additional information from the advanced The safety module has raised an indica- safety unit.

  • Page 57: Technical Data

    1) At sea level 2) Proof tests can only be performed at Danfoss facilities when the drive is refurbished. 3) Input to output response time with shielded cables. Otherwise, a maximum of 20 ms might be added to this value under worst case EMC conditions.

  • Page 58: Operating Conditions

    For PD2 condensing environments, the product must be installed in IP54/NEMA 12 cabi- net as per EN IEC 60529 AMD 2:2013, or equivalent. Check the operating conditions for each drive from the product-specific design guide or operating guide. Latest versions of Danfoss product guides are available for download at https://www.danfoss.com/en/service-and-support/documentation/.

  • Page 59: Cable Specifications

    Cross-section [mm (AWG)] Solid 0.5–1.5 (24–16) 10 (0.4) Flexible 0.5–1.5 (24–16) 10 (0.4) Flexible with ferrule w/o plastic sleeve 0.5–1.5 (24–16) 10 (0.4) Flexible with ferrule w plastic sleeve 0.5 (24) 10 (0.4) Danfoss A/S © 2024.08 AQ319741840653en-000401 / 136R0268 |...
  • Page 60 Operating Guide | iC7-Automation Functional Safety Functional Safety for Frequency Converters, Upgradable (+BEF2) | Danfoss A/S © 2024.08 AQ319741840653en-000401 / 136R0268...
  • Page 61  ...
  • Page 62 Danfoss reserves the right to alter its products without notice. This also applies to products ordered but not delivered provided that such alterations can be made without changes to form, fit or function of the product. All trademarks in this material are property of Danfoss A/S or Danfoss group companies.