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vacon 100 optbj safety manual

1. Fax 358 0 201 212 205 GENERAL VACON 9 Safe Stop 1 551 The 551 safety function 15 realized in compliance with type of the drives safety standard EN 61800 5 2 C The PDS SR initiates the motor deceleration and initiates the STO function after an application specific time delay The SS1 safety function has been designed for use accordance with the following standards EN 61800 5 2 Safe Stop 1 551 SIL2 EN ISO 13849 1 Category EN 62061 SILCL2 IEC 61508 SIL2 The function also corresponds to a controlled stop in accordance with the stop cat 1 EN 60204 1 Motor Thermistor Over temperature protection according to 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 OPTBJ board are described in this manual VTT 2 Technical Research Centre of Finland 2 1 REFERENCES Vacon 100 Installation and Application manuals are downloadable at www vacon com Support amp downloads Vacon manuals Vacon 100 manuals 24 hour support 358 0 201 212 575 Email vacon avacon com 10 INSTALLATION OPTBJ BOARD 3 INSTALLATION OPTBJ BORRD Open the cover of the AC drive 11573 00 The relay outputs and other l O terminals may have a dangerous control voltage present e
2. Short circuit and earth N O 24V fault protected supply w1 3045 emf The figure above presents a connection example of OPTBJ board for STO safety function with reset The switch S1 is connected with 4 wires to the OPTBJ board as shown above The digital input 3 DIN3 for example is wired for the fault reset function The reset function not part of any safety function can be programmed to any of the available digital inputs The power supply to S1 may come from control board connector pins 6 amp 7 in Figure above or it may also be external if earth fault and short circuit protected 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 30 SafeTorqueOff To start the motor operation again the following sequence is performed e Release the switch S1 contacts closed The hardware is now enabled but the drive continues to dis play the fault 30 SafeTorqueOff e Acknowledge the releasing of switch by edge sensitive reset function The drive returns to the ready state e Giving a valid start command will start running the motor NOTE The Vacon 100 default application software uses edge sensitive start as default start com mand for preventing unexpected startup from STO state NOTE For EN 60204 1 emergency stop according to stop category 0 use the emergency stop but ton Tel 358 0 201 2121 Fax 3
3. 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 7 Safe Stop 1 SS1 Time Delayed Safety Relay Vacon 100 Safe Torque Off STO 11579 uk Figure 7 Safe Stop 1 SS1 safety function Tel 358 0 201 2121 Fax 358 0 201 212 205 STO AND 554 SAFETY FUNCTIONS VACON 19 Figure 8 shows the connection principle of Safe Stop 1 safety function as specified in figure 6 e 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 Vacon 100 drive The general digital input must be programmed to execute the drive stop command and initiates the drive stop function without a time delay must be set to stop by ramp and causes motor deceleration If the SS1 behavior of Figure 6 is required then it must be ensured that the ramp stop 15 activated when the stop signal is received It is the responsibility of the system designer to verify this Safety Relay with timer Switch Ramp stop Vacon 100 control STO channel 1 STO channel 2 1 1 OPTBJ board 1 1 Power Unit 11577_uk Figure 8 The connection principle of Safe Stop 1 551 CAUTION The system designer user is responsible for understanding a
4. will stop by coasting The drive will indicate 30 SafeTorqueoff To start the motor operation again following sequence is performed e Release the switch S1 contacts closed The hardware is now enabled but the drive continues to dis play the fault 30 SafeTorqueOff e Acknowledge the releasing of switch by edge sensitive reset function The drive returns to the ready state e Giving a valid start command will start running the motor More information on the safety relay module may be found in the safety relay documentation NOTE The Vacon 100 default application software uses edge sensitive start as default start com mand for preventing unexpected startup from STO state NOTE For EN 60204 1 emergency stop according to stop category use emergency stop button 24 hour support 358 0 201 212 575 Email vacon avacon com VACON 26 COMMISSIONING 6 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 NOTE The user is responsible for excluding faults in the external wiring 6 1 GENERAL WIRING INSTRUCTIONS The wiring should be done according to the general wiring instructions for the specific prod uct where OPTBJ is installed Shielded cable is required for connecting the OPTBJ board EN 60204 1 part 13 5 The voltage drop from supply point to load must not exceed 5 In practice due to e
5. 27 6 3 Testing the Safe Torque Off STO or Safe Stop 1 551 safety functions 28 7 uri cet 29 7 1 Faults related to the Safe Torque Off STO or Safe Stop 1 551 safety functions 29 8 Thermistor function ATEX 31 gt Rm 34 8 1 1 Functional description ROME 34 8 1 2 Hardware and 34 AER E E AE 34 sm Short circuit MOM ERN E UT 35 CONAS ON 36 8 2 1 General wiring pita anm 36 8 2 2 Fault diagnosis of thermistor function aa 36 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 t l charger les versions anglaise et francaise des manuels produit contenant l ensemble des informations de s curit avertissements et mises en garde applicables sur le site www vacon com downloads 24 hour support 358 0 201 212 575 Email vacon avacon com 2 APPROVALS 1 APPROVALS VACON DRIVEN BY DRIVES 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 f
6. TORQUE OFF STO OR SAFE STOP 1 SS1 SAFETY FUNCTIONS NOTE Before testing the STO or SS1 safety functions make sure that the checklist Chapter 6 2 is inspected and completed 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 Concerning the 551 safety function make sure by testing that the drive s stop by ramp func tion 1 working In accordance with the process requirements NOTE If the STO safety function is used in low demand operating mode it must be tested peri odically at least once a year When the STO safety function is activated a code Fault 30 SafeTorqueOff appears on the control keypad display This indicates that the STO safety function is active After STO has been deactivated the fault remains active until the fault is acknowledged Tel 358 0 201 2121 Fax 358 0 201 212 205 MAINTENANCE 7 MAINTENANCE VACON 29 CAUTION If any service or repair is to be conducted on the drive installed with board please follow the check list given in Chapter 6 2 CAUTION During maintenance breaks or in case of service repair the OPTBJ 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 func tional by testing them See Chapter 6 3 7 1 FAULTS RELATED TO THE
7. drive cover and run the cable as shown in picture NOTE When planning the cable runs remember to keep the distance between OPTBJ cables and the motor cable at a minimum of 30 cm It is rec ommended to route the OPTBJ cables away from the power cables as shown in the picture NS OPTBJ cables 11572 uk Tel 358 0 201 2121 Fax 358 0 201 212 205 BOARD LAYOUT 13 4 OPTBJ BORRD LAYOUT Jumper for STO board activation Place here the Thermistor Input Thermistor active 4000 ohm PUMPET ter Serecune thermistor short circuit supervision 3 pin jumper from the control board After being active the fault can be reset if resistance is lt 2000 ohm TI1 1280 1 um ej X23 On Off 29 Thermistor short for STO function 25 circuit supervision STO1 O 5 01 STO2 O STO inputs 3038 emf Figure 1 board layout 5 e X10 gt 4 1 BOARD JUMPERS There are two jumpers the OPTBJ option board The jumpers are described below Jumper X23 short circuit supervision Short circuit supervision ON eee Short circuit supervision OFF 0 9 e Jumper X10 STO board activation STO board not activated STO board activated take the 3 pin jumper from the control 9 e ej board see figure below Factory default 3039 emf Figure 2 OPTBJ board jumpers To activate the OPTBJ board you
8. note in this page It can be used as an overtemperature tripping device for motors in explosive area EX motors NOTE The OPTBJ board also contains the Safe Torque Off STO safety function When STO is not intended to be used inputs STOT OPTBJ 1 STO2 OPTBJ 3 are to be connected to 24V for ex ample pin 6 in Vacon 100 control board STO1 OPTBJ 2 STO2 OPTBJ 4 are to be connected to GND for example pin 7 or 13 on Vacon 100 control board NOTE Safety devices like the OPTBJ board must be correctly incorporated into the entire system The functionality of the OPTBJ 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 CAUTION The information in this manual provides guidance on the use of therm istor function for protecting overheating of motors in explosive atmosphere How ever 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 OPTBJ 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 OPTBJ board with Vacon 100 control is used to protect the overheating of motors in explosive atmosphere The drive itself including OP
9. slot E Install the board to slot E Install the STO jumper to the control board when the OPTBJ board has been removed from the drive See ch 3 1 and 3 1 1 Check the installation of the STO jumper on the control board See ch 3 1 and 3 1 1 Check the installation of STO jumper switch on the OPTBJ board See ch 3 1 and 3 1 1 Check the installation of the OPTBJ board Restart the drive Change the OPTBJ board if nec essary Should the fault re occur con tact the distributor near to you VACON 30 Safety diagnostics Safety diagnostics Safety diagnostics Safety diagnostics Safety diagnostics Safety diagnostics Safety diagnostics Safety diagnostics The hardware does not support the OPTBJ board There is a diagnostic failure in the STO safety function This fault occurs when the STO inputs are ina different state for more than 100 ms Atex thermistor diagnostic fault Atex thermistor short circuit Problem occured in internal Safety circuit Overvoltage detected in safety option board Undervoltage detected in safety option board Internal failure detected in safety option board CPU or memory handling Internal failure detected in safety function Tel 358 0 201 2121 Fax 358 0 201 212 205 MAINTENANCE Restart the drive Should the fault re occur con tact the distributor near to you Restart the drive If the restart does not help change the OPTBJ bo
10. 08 2010 Low Demand Mode 24 hour support 358 0 201 212 575 Email vacon avacon com SIL 3 2 5 10 10 hour 1 SIL CL 3 2 5 10 10 hour 1 PLe 2600 years medium Category 3 SIL 3 2 5 10 10 hour 1 SIL 3 2 2 10 hour 20 years 1 SIL 3 3 1 10 19 hour 1 SIL CL 3 3 1x10 8 hour 1 1100 years medium Category 3 513 3 1 10 9 hour HFT 1 SIL 3 PF Dayo 2 7 10 hour 20 years 1 22 STO AND 551 SAFETY FUNCTIONS Safe Stop SS1 safety related data NOTE The following chapter is only an informative example of combining products The 551 safety function consists of two subsystems with different safety related data The subsys tem consisting of the time delayed safety relay is manufactured for example by PHOENIX CON TACT The following types are available from this manufacturer e PSR SCP 24DC ESD 5X1 1X2 300 or e PSR SPP 24DC ESD 5X1 1X2 300 See manufacturer user manual for more information regarding the time delayed safety relay PSR SC PP 24DC ESD 5X1 1X2 300 safety related data from user manual and certificate Vacon 100 STO safety related data DIN EN ISO 13849 1 5 9 61508 TEN ategory 3 DIN EN ISO 13849 1 PFH 1 89 10 ho
11. 081 DIN 440 8 1 3 ATEX FUNCTION When drive is connected to the main power and if the motor temperature is below overtemperature limits see Figure 11 the drive goes to ready state The motor may start after a valid start com mand If the motor temperature is above the overtemperature limits see Figure 11 fault 29 Atex therm istor is activated When the resistance of the thermistor s mounted in the motor goes above 4 kOhm due to motor overheating the drive modulation is disabled within 20ms According to Figure 11 when the temperature falls below 2 kOhm the thermistor function allows fault reset and entering to ready state Tel 358 0 201 2121 Fax 358 0 201 212 205 THERMISTOR FUNCTION ATEX VACON 35 8 1 4 SHORT CIRCUIT MONITORING The thermistor inputs 1 and 11 are monitored for short circuit short circuit is detected the drive modulation is disabled within 20ms Fault 30 Safety diagnostic subcode 522 is generated When the short circuit has been removed the drive can be reset only after a power recycle The short circuit monitoring can be enabled or disabled using the jumper X23 in ON or OFF position respectively The jumper is set in ON position by factory default 24 hour support 358 0 201 212 575 Email vacon avacon com VACON 36 THERMISTOR FUNCTION ATEX 8 2 COMMISSIONING NOTE Installation testing and service work on the OPTBJ board can be performed only by quali f
12. 58 0 201 212 205 STO AND 554 SAFETY FUNCTIONS VACON 25 Example 3 OPTBJ board with 551 and safety reset EN 60204 1 stop category 1 MAIN CIRCUIT L1 L2 L3 PE PE hid SPEED REFERENCE RSI RAMP STOP Ccw CD q w12 ash 2p lt RS2 1 AO GND 24Vin RS485 RS485 OFF 5485 1 V Al2 ooo AN OFF DGND Basic I O PE 01 5 01 STO2 STO2 ROIC ROINO Ti Installed poets LO O XS oq o os ox os Store ON o n Bridge between 533 535 for automatic reset e S1 24VDC 12 22 Not allowed with emergency stop 2 13 ii il 41 A1 S10 511 S12 S21 S22 33 34 S35 ECIN DD PHOENIX CONTACT 14 24 34 42 A2 PSR SCP 24DC ESD 5X1 1X2 300 _ J OVDC 852 4 oV 24V Short circuit and earth fault protected supply 3046 emf The figure above presents a connection example of OPTBJ board for SS1 safety function with ex ternal safety relay module and with safety reset The external safety relay module is connected to the switch S1 The used power supply to switch 51 is 230 VAC as an example The safety relay module is connected to OPTBJ board with 4 wires as shown in Figure above When the switch S1 is activated contacts open the drive will go to STO state and motor if running
13. SAFE TORQUE OFF STO SAFE STOP 1 551 SAFETY FUNCTIONS The table below shows the normal fault generated when STO safety function Is active Feat STO activated through the EM OPTBJ option board STO function activated Drive is in safe state The table below shows faults that may be generated from the software part that monitors the hard ware related to the STO safety function If some of the faults listed below occur DO NOT reset the fault o Een _ Safety configuration Safety configuration Safety configuration Safety configuration Safety configuration Safety configuration 30 Safety configuration 506 STO jumper is installed the control board More than one OPTBJ option board detected in the drive OPTBJ option board installed to a wrong slot STO jumper missing from the control board Problem detected in STO jumper installation on the con trol board Problem detected in STO jumper installation on the OPTBJ board Communication has been failed between the control board and OPTBJ option board 24 hour support 358 0 201 212 575 Email vacon avacon com Remove the STO jumper from the control board See ch 3 1 and 3 1 1 Only one OPTBJ board is sup ported by the drive Remove other OPTBJ boards from the drive except from slot E OPTBJ option board can only be installed to
14. TBJ board can not be installed in explosive atmosphere NOTE The 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 For example in the Exe and ExnA motors the PTC sensors must 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 C 50 C 24 hour support 358 0 201 212 575 Email vacon avacon com 32 THERMISTOR FUNCTION ATEX VACON 100 CONTROL UNIT OPT BJ board slot E Atex Safety Thermistor Function Atex Safety Function Control board RO STO1 asm 2179 C IU POWER UNIT Hardware Hardware STO 1 STO 2 11575A_uk Figure 9 Thermistor function principle in Vacon 100 frequency converter with the board MR4 10 Tel 358 0 201 2121 Fax 358 0 201 212 205 THERMISTOR FUNCTION ATEX VACON 33 OPT BJ board slot E Atex Safety Thermistor TZ RO Atex Safety a Function s TALL Control board SLAVE MASTER POWER UNIT POWER UNIT 11654 uk Figure 10 STO principle with OPTBJ board and Vacon 100 control board MR12 24 hour support 358 0 201 212 575 Em
15. VACON 100 AC DRIVES OPTBJ STO AND ATEX OPTION BOARD SAFETY MANUAL VACON DRIVEN BY DRIVES VACON 1 TABLE OF CONTENTS Document DPD00470C Release date 20022015 1 ADD OVIL mr ee nes fenton ca Sets ene ene ees 2 8 9 3 Installation of OP TBS board 10 A veu S3 enn eo uus cest ea sa EESEE 13 MIP I Rm 13 4 2 STO jumpers on the Vacon 100 14 o fUNCHONS 15 51 Safe Torque Off 5 eu gasta ieu tu ep RR rare 15 56 2 Gafe Stop T991 Principle MN Umm 18 Deo Technical OS TAINS 20 eee eee ee n 20 20 SS EE I Mero 21 5 3 4 Safety related data according to the standard 21 MNT TM 23 6 COMMISSIONING S Ur NUI DU M QNM MES 26 0 1 WINING FCD OFIS uU 26 6 2 Checklist for commissioning the OPTBJ
16. acon Plc Runsorintie 7 65380 Vaasa Finland Subject to change without prior notice 2015 Vacon Plc Document ID f 0 C Rev C D P DO O 4 Sales code DOC OPTBJ DLUK
17. ail VACON 34 THERMISTOR FUNCTION ATEX 8 1 TECHNICAL DATA 8 1 1 FUNCTIONAL DESCRIPTION The thermistor supervision circuit of the board is designed to provide a reliable way of dis abling 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 15 avoided The thermistor supervision circuit meets the requirements the ATEX directive by directly activat ing the STO safety function of the Vacon 100 See Figure 9 and thus provides a reliable software and parameter independent way of preventing the energy supply to the motor 8 1 2 HARDWARE AND CONNECTIONS See Chapter 9 3 2 The thermistor is connected between the terminals 28 11 and 29 TI1 of the OPTBJ board The optocoupler isolates the thermistor inputs from the control board potential If 230VAC 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 R 100 OPTBJ Trip level 200 40 to Ready level 11580 uk Figure 11 Typical characteristics of a motor protection sensor as specified in DIN 44
18. ard Should the fault re occur con tact the distributor near to you Deliver the fault report to the distributor see fault details for more information Restart the drive If the restart does not help change the OPTBJ board Should the fault re occur con tact the distributor near to you Check the connection of the Atex thermistor Check the thermistor Restart the drive If the restart does not help change the OPTBJ board Should the fault re occur con tact the distributor near to you Reset the drive and restart If the fault reoccurs contact your nearest distributor Reset the drive and restart If the fault reoccurs contact your nearest distributor Reset the drive and restart If the fault reoccurs contact your nearest distributor Reset the drive and restart If the fault reoccurs contact your nearest distributor Reset the drive and restart If the fault reoccurs contact your nearest distributor THERMISTOR FUNCTION ATEX VACON 31 8 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 VTT 06 ATEX 048X category 2 in the G area area in which 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
19. ctrical equipment of machines Part 1 General requirements EN 61326 3 1 2008 Electrical equipment for measurement control and laboratory use EMC Part 3 1 Immunity requirements for safety related systems and for equipment intended to perform safety related functions functional safety Signature In Vaasa 10th of February 2015 Vesa Laisi President and CEO Tel 358 0 201 2121 Fax 358 0 201 212 205 APPROVALS VACON 3 EC Type Examination Certificate Reg No 01 205 5216 01 15 Product tested Safety Function Safe Torque Certificate Vacon PLC Off STO within Adjustable holder Runsorintie 7 Frequency AC Drive 65380 Vaasa Finland Type designation Vacon 100 AC Drive with STO and ATEX option board Frame Sizes MR4 to MR10 VACON 0100 3L xxxx y Details see Revision Release List Codes and standards EN 61800 5 1 2007 EN 62061 2005 AC 2010 EN 61800 5 2 2007 A1 2013 EN 61800 3 2004 A1 2012 EN 61508 Parts 1 7 2010 EN ISO 13849 1 2008 2009 EN 60204 1 2006 1 2009 AC 2010 in extracts Intended application The safety function Safe Torque Off complies with the requirements of the relevant standards PL Cat 3 acc to EN ISO 13849 1 SIL CL 3 acc to EN 61800 5 2 EN 62061 IEC 61508 and can be used in applications up to PL e acc to EN ISO 13849 1 and SIL 3 acc to EN 62061 IEC 61508 Specific requirements The instructions of the associated Installatio
20. e OPTBJ 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 EN12100 Part 1 Part 2 amp ISO 14121 1 provide methods for designing safe ma chinery and for carrying out a risk assessment CAUTION The information in this manual provides guidance on the use of the safety functions that OPTBJ option board provides together with Vacon 100 con trol board This information is in compliance with accepted practice and regula tions 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 5 1 SAFE TORQUE OFF STO PRINCIPLE The 5 safety function of the OPTBJ board allows the drive output to be disabled so that the drive cannot generate torque in the motor shaft For STO the OPT BJ board has two separate galvanically isolated inputs STOT and STO2 NOTE STO inputs must be connected to 24V signal so that the drive can to the enable state The STO safety function is achieved by disabling the drive modulation The drive modulation is dis abled through two independent paths controlled by STO1 and STO2 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 elec
21. e without signatures shall not be valid This certificate including the schedule may only be reproduced in its entirety and without any change 24 hour support 358 0 201 212 575 Email vacon avacon com VACON 8 GENERAL 2 GENERAL NOTE These are the original instructions NOTE Designing of safety related systems requires special knowledge and skills Only qualified persons are permitted to install and set up the OPTBJ board This document covers the OPTBJ option board 70CVB01380 functionality together with Vacon 100 Control board 70CVB01582 The OPTBJ option board together with Vacon 100 control board provides the following safety func tions with Vacon 100 products The n safety related abbreviations and expressions have been used in this manual EI dangerous random Faure per our _ Category ora safe functo from EN SO 9809 12006 I MTTFa Mean time to dangerous failure O OOOO Mean time to dangerous failure DCavg diagnostic coverage O O O00000 Average diagnostic coverage PFDavyg Average probability of random hardware failure demand Average p of random hardware failure on demand Safe Torque Off STO The hardware based Safe Torque Off safety function prevents the drive from generating torque on the motor shaft The STO safety function has been designed for use in accordance with the followi
22. intie 7 FI 65380 VAASA Finland 7 This equipment or protective system and any acceptable variations thereto are specified in the schedule and possible supplement s to this Certificate and the documents therein referred to 8 Expert Services Ltd notified body number 0537 in accordance with Article 9 of the Council Directive 94 9 EC of March 1994 certifies that this equipment or protective system has been found to comply with the Essential Health and Safety Requirements relating to the design and construction of equipment and protective system intended for use in potentially explosive atmospheres given in Annex II to the Directive The examination and test results are recorded in confidential reports nos VTT S 05774 06 and 968 M 350 00 12 by T V Rheinland Industrie Service GmbH VTT Expert Services Ltd Tel 358 20 722 111 Kivimichentie 4 Espoo Fax 358 20 722 7042 P O Box 1001 F1 02044 VTT Finland 1005 EN ISO IEC 17020 Tel 358 0 201 2121 Fax 358 0 201 212 205 APPROVALS VACON 5 9 Compliance with the Essential Health and Safety Requirements has been assured by compliance with EN ISO 13849 1 2006 EN ISO 13849 2 2003 EN 60079 14 2007 EN 61508 3 2010 EN 50495 2010 10 If the sign X is placed after the certificate number it indicates that the equipment or protective system is subject to special conditions for safe use specified in the schedule to th
23. is certificate 11 This EC Type examination certificate relates only to the design examination and tests of the specified equipment or protective system in accordance to the directive 94 9 EC Further requirements of the Directive apply to the manufacturing process and supply of this equipment or protective system These are not covered by this certificate 12 The marking of the equipment or protective system shall include the following II 2 GD Espoo 26 4 2012 VTT Expert Services Ltd 4 C Olavi Nevalainen Risto Sulonen Deputy Service Manager Product Manager Certificate without signatures shall not be valid This certificate including the schedule may only be reproduced in its entirety and without any change 24 hour support 358 0 201 212 575 Email vacon avacon com VACON 9 6 APPROVALS 13 Schedule 14 EC TYPE EXAMINATION CERTIFICATE VTT 06 ATEX 048X Issue 1 15 Description of Equipment Thermal motor protection system type OPTBJ consist one safe disable amp ATEX option board with possibility to connect to temperature sensor PTC The temperature sensor is not included in this certificate The ATEX safety function may be used with all Vacon 100 drives that are controlled with the M platform STO option board Documents specifying the equipment Functional safety management plan for the M Platform STO rev 1 3 16 Report No VTT S 05774 06 and 968 M 350 00 12 TUV Rhein
24. land Industrie Service GmbH 17 Special conditions for safe use 1 Inthe case of Exe and ExnA motors the end user has to confirm that the installation of measurement circuit is installed according to area classification E g in Exe and ExnA motors PTC sensors shall be certified together with the motor according to requirements of the type of protection 2 The allowed ambient temperature range is 10 C 50 C 18 Essential Health and Safety Requirements Assessment using standards referred in point 9 have confirmed compliance with the Directive 94 9 EC Annex II and in particular point 1 5 The device themselves are to be installed outside potentially explosive atmospheres article 1 section 2 of the Directive Certificate without signatures shall not be valid This certificate including the schedule may only be reproduced in its entirety and without any change Tel 358 0 201 2121 Fax 358 0 201 212 205 APPROVALS VACON 7 Certificate history 19 62006 VTT S 05774 06 Supplement 1 26 6 2008 The introduction of new revisions and 2 and and STO function 6 4 2010 26 4 2012 968 350 00 12 The introduction of M Platform STO function and changing equipment name and type designation Updating the certificate with the latest edition of relevant standards Espoo 26 4 2012 VTT Expert Services Ltd Olavi Nevalainen Risto Sulonen Deputy Service Manager Product Manager Certificat
25. lectromagnetic 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 in order to avoid unwanted tripping Cable recommendation E g 2x2x0 75mm low voltage single shielded twisted pair cable Maximum length 200 m between STO inputs and the operating contact Tel 358 0 201 2121 Fax 358 0 201 212 205 COMMISSIONING VACON 27 6 2 CHECKLIST FOR COMMISSIONING THE OPTBJ BOARD Has arisk assessment of the system been carried out to ensure that us ing the OPTBJ board Safe Torque Off STO or Safe Stop 1 551 safety function is safe and according to the local regulations The shaft of a permanent magnet motor might in an IGBT fault situation rotate up to 180 degrees around the pole of the motor Has It been en sured that the system Is designed in such a way that the this can be ac cepted Have process requirements including deceleration time been consid ered for correct execution of Safe Stop 1 551 safety function and are the corresponding settings done 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 Have the STO and SS1 safety functions been tested properly according to Chapter 5 3 24 hour support 358 0 201 212 575 Email vacon avacon com VACON 28 COMMISSIONING 6 3 TESTING THE SAFE
26. led persons NOTE It is not allowed to perform any repair work on the OPTBJ board Return faulty boards to Vacon for analysis NOTE It is recommended to test the ATEX functionality using thermistor input on OPTBJ board pe riodically typically once a year For testing activate the thermistor functionality e g remove Atex thermistor plug from the OPTBJ board The drive enters to fault state and indicates fault 29 thermistor fault subcode 280 8 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 shielded control cable must be used See also Chapter 3 Maximum cable length without Maximum cable length without short short circuit monitoring circuit monitoring X23 OFF X23 ON gt 1 5sqmm 1500 meters 290 meters 8 2 2 FAULT DIAGNOSIS OF THERMISTOR FUNCTION The table below shows the normal fault warning generated when thermistor input is active Fault code Explanation Correcting measures measures Atex thermistor has a Atex thermistor overtemperature See the fault table in chapter 6 1 Tel 358 0 201 2121 Fax 358 0 201 212 205 VACON DRIVEN BY DRIVES Find your nearest Vacon office on the Internet at WWW Vacon com Manual authoring documentation dvacon com V
27. must take the three pin jumper from the drive control board and place it to the OPTBJ board jumper X10 See the next chapter for more information NOTE If there are problems with the jumpers see chapter 7 1 24 hour support 358 0 201 212 575 Email vacon avacon com VACON 14 BOARD LAYOUT 4 2 STO JUMPERS ON THE VACON 100 DRIVE 21022 NN g Cy dethemst LED 200000 OFF terminatio df 3049 emf Figure 3 STO jumper location on Vacon 100 Open the main cover and the inner cover to reveal the jumper Tel 358 0 201 2121 Fax 358 0 201 212 205 STO AND 554 SAFETY FUNCTIONS VACON 15 5 STO AND 551 SAFETY FUNCTIONS The safety functions of the OPTBJ board such as the technical principle and data wiring examples and commissioning will be described in this chapter NOTE The use of STO SS1 or other safety functions does not itself ensure safety An overall risk evaluation 15 required in order to make sure that the commissioned system 15 safe Safety devices like th
28. n and Operating Manual shall be considered It is confirmed that the product under test complies with the requirements for machines defined in Annex of the EC Directive 2006 42 EC Valid until 2020 01 30 E Mail industrie service de tuv com The issue of this certificate is based upon an examination whose results are documented in Report No 968 M 350 01 15 dated 2015 01 30 gt This certificate is valid only for products which are dentical Math th product tested It becomes invalid at any change of the codes and standards forming the basis of te RA 57 Fax 49 30 7562 1370 E 49 30 7562 15 Berlin 2015 01 30 TUV Rheinland Industrie Service GmbH Alboinstr 56 12103 Berlin Germany Certification Body for Machinery NB 0035 Dipl Ing Eberhard Frejno Tel TUEV and TUV are registered trademarks Utilisation and application requires prior approval www fs products com www tuy com AX T vRheinland Precisely Right 10 222 12 12 E A4 24 hour support 358 0 201 212 575 Email vacon avacon com VACON 9 4 APPROVALS 1 EXAMINATION CERTIFICATE 2 Equipment or Protective System Intended for use in Potentially explosive atmospheres Directive 94 9 EC 3 Reference VTT 06 048 Issue 1 4 Equipment Thermal motor protection system for Vacon 100 drives Certified types Manufactured by Vacon Plc 6 Address Runsor
29. nd setting the time delay of the safety relay as it is process machine dependent e time delay must be set to a greater value than the deceleration time of the drive The motor deceleration time is process machine dependent e The stop function of the drive needs to be correctly set for the process machine Activating the SS1 safety function must execute the configured stop in the drive In the Vacon 100 default application software it is recom mended to use the Quick Stop functionality for this purpose In case of a single fault the drive may not ramp down but is only put to STO mode after the config ured time delay CAUTION The control place must be set according to the application require ments See Chapter 5 4 concerning the parametrizing of Safe Stop 1 and Chapter 5 3 5 for the wiring of Safe Stop 1 24 hour support 358 0 201 212 575 Email vacon avacon com 20 STO AND 551 SAFETY FUNCTIONS 5 3 TECHNICAL DETAILS 5 3 1 RESPONSE TIMES Activation De Safety function activation time Safe Torque Off STO Table 1 STO response times 5 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 15 disabled by making a short circuit to the ter minals and setting the jumper X23 OFF state The thermistor input operation and instruction
30. ng standards EN 61800 5 2 Safe Torque Off STO SIL3 EN ISO 13849 1 Category EN 62061 SILCL3 IEC 61508 SIL3 The function also corresponds to an uncontrolled stop in accordance with the stop category 0 EN 60204 1 e The STO safety function has been certified by T V Rheinland 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 applica tion requirements Required external components may be for example e Appropriate lockable switch e A safety relay providing a reset function NOTE The safety functions of OPTBJ do not comply with Emergency Switching Off according to EN 60204 1 NOTE Do not use the STO function as a standard stop function of the drive NOTE In an IGBT fault situation the shaft of a permanent magnet motor can rotate up to 180 degrees around the pole of the motor NOTE If the pollution degree 2 cannot be guaranteed use the IP54 protection class CAUTION The OPTBJ 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 for example using an external supply disconnecting switch See for example EN60204 1 Chapter 6 3 Tel 358 0 201 2121
31. que Off safety function without reset The switch S1 is connected with 4 wires to the OPTBJ board as shown above The power supply to 1 may come from control board connector pins 6 amp 7 in the above Figure 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 30 SafelorqueOff To start the motor operation again the following sequence is performed e Release the switch S1 contacts closed The hardware is now enabled but the drive continues to dis play the fault 30 SafeTorqueOff e Acknowledge the releasing of switch by edge sensitive reset function The drive returns to the ready state e Giving a valid start command will start running the motor NOTE The Vacon 100 default application software uses edge sensitive start as default start com mand for preventing unexpected startup from STO state 24 hour support 358 0 201 212 575 Email vacon avacon com VACON 24 STO AND SS1 SAFETY FUNCTIONS Example 2 OPTBJ board with reset for Safe Torque Off or EN 60204 1 stop category 0 MAIN CIRCUIT L1 13 1 3 5 START STOP RESET 2 4 6 SPEED REFERENCE TUS 1 12 13 24Vout AO1 AO GND 24Vin ON OFF RS485 A V AOI A V A2 A ON OFF DGND STO2 RO1C RO1 NO 11 Installed 10 Safe torque off 1 11 21 q 12
32. s are presented in chapter 7 1 Terminal Technicalinformation Technical information LIO 5 01 Isolated STO input 1 24V 20 10 15 _ Isolated STO input 1 24V 20 10 15 Virtual GND 1 Relayoutput1 NO Switching capacity e 24VDC 8A e 250VAC 8A e 125VDC 0 4A Min switching load 5V 10mA Table 2 OPTBJ 1 0 terminals If 230VAC 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 Vsto1 Vsro1 Vsto2 Vsro2 STO state Table 3 STO function truth table Tel 358 0 201 2121 Fax 358 0 201 212 205 STO AND 554 SAFETY FUNCTIONS 21 5 3 3 RELAY OUTPUT When the STO function is active the relay output is closed When the STO function Is inactive the relay output is open When STO function has detected a non resettable diagnostics fault the relay output toggles at a frequency of one hertz NOTE The ATEX input has no effect on the relay output A CAUTION The relay output 1 non safety related functionality 5 3 4 SAFETY RELATED DATA ACCORDING TO THE STANDARD Table 4 Safe Torque Off STO safety related data 61800 5 2 2007 62061 2005 EN ISO 13849 1 2006 IEC 61508 2010 High Demand Mode IEC 615
33. tronics 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 Figures 4 and 5 24 hour support 358 0 201 212 575 Email vacon avacon com VACON 16 STO AND SS1 SAFETY FUNCTIONS VACON 100 CONTROL UNIT OPT BJ board slot E T Atex Safety Thermistor LJ Function Atex Safety Function Control board RO STO1 A te 211 C U POWER UNIT Hardware Hardware STO 1 STO 2 11575A_uk Figure 4 STO principle with OPTBJ board and Vacon 100 control board MR4 10 Tel 358 0 201 2121 e Fax 358 0 201 212 205 STO AND 554 SAFETY FUNCTIONS 17 VACON 100 CONTROL UNIT OPT BJ board slot Control board T Atex Safety Thermistor Function RO Atex Safety m Function w TA mt T Ae SLAVE MASTER POWER UNIT POWER UNIT 11654 uk Figure 5 STO principle with board and Vacon 100 control board MR12 24 hour support 358 0 201 212 575 Email vacon avacon com VACON 18 STO AND 551 SAFETY FUNCTIONS 5 2 SAFE STOP 1 551 PRINCIPLE After a safe stop command the motor starts decelerating and SS1 safety function initiates the STO after a user set time delay Frequency Stop Motor deceleration factual Safe Torque Off STO Time delay Time 11578 uk Figure 6 The principle of Safe Stop 1 EN 61800 5 2 SS1 type c
34. unctions of the following product Product name Vacon option board to be used with Vacon 100 family products Product Identification 7OCVB01380 Product Safety Functions Safe Torque Off Specified in EN 61800 5 2 fulfils all of the relevant safety component requirements of EC Machinery Directive 2006 42 Notified body that carried out the EC type examination T V Rheinland Industrie Service GmbH NB0035 Am Grauen Stein 51105 Koln Germany The following standards and or technical specifications referenced below were used EN 61800 5 2 2007 Adjustable speed electrical power drive systems Part 5 2 Safety requirements Functional EN 61800 5 1 2007 only for LV Directive compliance Adjustable speed electrical power drive systems Part 5 2 Safety requirements Electrical thermal and energy EN 61800 3 2004 A1 2012 only for EMC Directive compliance Adjustable speed electrical power drive systems Part 3 EMC requirements and specific test methods EN ISO 13849 1 2008 AC 2009 Safety of machinery Safety related parts of control systems Part 1 General principles for design EN 62061 2005 AC 2010 Safety of machinery Functional safety of safety related electrical electronic and programmable electronic control systems IEC 61508 Parts 1 7 2010 Functional safety of electrical electronic programmable electronic safety related systems EN 60204 1 2006 A1 2009 AC 2010 extracts Safety of machinery Ele
35. ur _ PFH 2 52 10 10 hour SubsysteMsafetyRelay SubsysteMyacon100STO Safe Stop 1 5591 safety related data EN 61800 5 2 151 2 IEC 61508 SiL 2 2 14 10 7 hour PL d DIN EN ISO 13849 1 C When the two subsystems are combined the maximum safety integrity Level or performance level reached is the level of the lower subsystem e SlL2and PLd The PFH value for a safety function of combined subsystems is the sum of all subsystems PFH values PFHss PFHsafety Relay sto 1 89 10 7 hour 2 52610 9 hour 2 14910 hour The result is within the requirements for SIL 2 and PL d Tel 358 0 201 2121 Fax 358 0 201 212 205 STO AND 554 SAFETY FUNCTIONS VACON 23 5 3 5 WIRING EXAMPLES The examples this chapter show the basic principles for wiring OPTBJ board Local standards and regulations should be always followed in the final design Example 1 OPTBJ board without reset for Safe Torque Off STO MAIN CIRCUIT 1 12 L3 START STOP SPEED REFERENCE Ccw PR cx W12 lish Tir 2sh 2 5 1 24Vin 85485 5485 ooo ARV Al ooo ON OFF DGND Basic 1 0 STO1 STO2 STO2 RO1 NO TH Installed Safe torque off 11 ex z 12 O Short circuit and earth O424v fault protected supply 3044 emf The figure above shows a connection example of OPTBJ board for Safe Tor
36. ven when Vacon 100 is disconnected from mains Slot coding 1 3040 emf NOTE Incompatible boards cannot be installed on Vacon 100 Compatible boards have a slot coding that enable the placing of the board see above Tel 358 0 201 2121 Fax 358 0 201 212 205 INSTALLATION OF OPTBJ BOARD VACON 11 Open the Inner cover to reveal the option board slots and install the board into slot E Close the inner cover NOTE See Chapter 4 1 for the jumper settings Z ethemet L A pA jesse TE 3041 emf Using the grounding clamp for control cable included in the delivery of the drive ground the shield of the OPTBJ cable to the frame of the AC drive NOTE Shielded cable must be used NOTE Grounding must be done according to best practice Grounding clamp for 4 2 CERERI control cable I 115744 uk 24 hour support 358 0 201 212 575 Email vacon avacon com VACON 12 INSTALLATION OPTBJ BOARD Unless already done for the other control cables cut free the opening on the AC drive cover for the OPTBJ cable protection class IP21 NOTE Cut the opening on the side of the slot E 11576_00 Remount the AC

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