Danfoss VLT Safety Option MCB 150 User manual

Installation Guide
VLT® Safety Option MCB 150/151

Contents
1 Introduction 7
1.1 Purpose of this Operating Guide 7
1.2 Available Resources 7
1.3 Document Version 7
1.4 Type Approvals and Certifications 8
2 Legal Information an Safety 9
2.1 Legal Information 9
2.2 Warranty and Liability 9
2.3 Safety Symbols 9
2.4 Qualified Personnel 9
2.5 Responsibilities of Users of PDS(SR) 10
2.6 Safety Precautions 10
2.7 Risk Assessment 12
3 Functions and Systems Overview 13
3.1 System Overview 13
3.1.1 Behavior of Holding Brake 14
3.1.2 Safety Certification 14
3.1.3 Implementation in Control Systems 14
3.2 Functions 15
3.2.1 Specification of Safety Functions 15
3.2.1.1 Performance Level (PL) and Safety Integrity Level (SIL) 15
3.2.2 Validation of Performance Level 15
3.2.3 Activation of Safety Functions 15
3.2.4 Simultaneous Activation of Safety Functions 16
3.2.5 Functional Proof Tests 17
3.2.6 PFD and PFH Definitions 18
3.2.7 Intended Use of the Safety Option 18
3.2.8 MCT 10 Set-up Software with Safe Plug-in 18
3.3 Unit Features 18
3.4 Front View 19
3.5 Categories of Safe Stop 20
3.5.1 Operation and Requirements 20
3.5.2 Safety Functions 20
3.5.3 Safe Torque Off - STO 21
3.5.4 Safe Stop 1 - SS1 22
3.5.4.1 SS1 Delay 22
3.5.4.1.1 Selecting the SS1 Settings 23
3.5.4.2 SS1 Delay with S-ramp Stop Profile 24
Contents
Installation Guide | VLT® Safety Option MCB 150/151
AQ279747441421en-000101 / 130R0292 | 3Danfoss A/S © 2018.09

3.5.4.3 SS1 Ramp 25
3.5.4.4 SS1 Ramp Slope 25
3.5.4.5 SS1 Ramp Time 26
3.5.5 Safely Limited Speed 27
3.5.5.1 SLS without Ramp 28
3.5.5.2 SLS with Ramp 29
3.5.5.2.1 Configuring SLS Operation 30
3.6 Inputs and Output 31
3.6.1 Inputs 31
3.6.2 Reset Input (DI2) 32
3.6.3 Output 32
3.6.4 Allowed Sensor Types on Digital Inputs 32
3.6.5 Reset 32
3.6.6 Signal Filtering 33
3.6.7 Stable Signal Time from Safe Outputs 33
3.6.8 Zero Speed Timer Error Detection 34
3.6.9 Yearly Test 34
3.6.10 Safety Parameter Settings 35
3.6.11 Encoder Interface 35
3.7 Limitations 35
3.7.1 Exceeded Limit Value and Internal Errors 35
3.7.2 Compatibility between Safety and Drive Function 35
4 Installation 37
4.1 Installing the Option 37
4.1.1 Safety Instructions 37
4.1.2 Requirements for Safe Use 37
4.1.3 Protected Cable Installation 38
4.1.4 Installing the Option 38
4.1.5 General Wiring Guidelines 41
4.1.6 Connector Pin Assignment 43
4.2 Encoder 44
4.2.1 Allowed Encoder Cable Length 44
4.2.2 Encoder Wiring Examples 45
4.2.3 Proximity Switch 46
4.2.4 VLT® Sensorless Safety MCB 159 47
4.2.4.1 Connecting a VLT® Sensorless Safety MCB 159 (MCB 151 Only) 48
4.3 Application Examples 49
4.3.1 Connecting Safe Digital Inputs 49
5 Commissioning 52
5.1 Before Commissioning 52
Contents
Installation Guide | VLT® Safety Option MCB 150/151
AQ279747441421en-000101 / 130R02924 | Danfoss A/S © 2018.09

5.1.1 Safety Guidelines 52
5.1.2 Commissioning Requirements 52
5.2 Initial Commissioning 53
5.2.1 Power-up/Self-test 53
5.2.2 Initial Commissioning 53
5.2.3 Safety Option Customization 54
5.2.4 Setting Up the Encoder 55
5.2.5 Commissioning Test 55
5.3 Operation 56
6 General Parameter Set-up 57
6.1 Configuration 57
6.1.1 General Parameter Set-up 57
6.1.2 Configuration of Safety Functions 57
6.1.3 Password Protection 58
6.1.3.1 Resetting the Password 58
6.2 Reset and Status over Fieldbus 59
6.2.1 Reset of Safety Option and Pending Safe Function 59
6.2.2 Retrieving Safety Option Status 59
6.3 Parameter List 63
7 Service and Repair 68
7.1 Updates, Servicing, and Modifications 68
7.2 Repair 68
7.3 Replacement of Safety Option 69
7.3.1 Before Removing the Safety Option 69
7.3.2 Removing the Safety Option 69
7.3.3 Replacing the Safety Option 69
7.3.4 Copying Safe Parameter Set-up 70
7.3.4.1 Password Protection LCP Copy and Safe Parameter Mismatch 70
7.4 Commissioning Test 74
7.4.1 Safety Guidelines 75
7.4.2 Before Running the Commissioning Test 75
7.4.2.1 Checking Effectiveness of Safety Functions 75
7.4.3 Safety Functions in the Drive 75
8 Warnings and Alarms 81
8.1 Fault Types and Messages 81
8.1.1 Messages 81
8.2 Warnings and Alarms 82
8.2.1 Safety Option Warning 89
8.2.2 Safety Option Reset Message 90
Contents
Installation Guide | VLT® Safety Option MCB 150/151
AQ279747441421en-000101 / 130R0292 | 5Danfoss A/S © 2018.09

9 Technical Specifications 92
9.1 Consumption 92
9.2 Inputs 92
9.2.1 Digital Inputs 92
9.2.2 TTL Encoder Input (VLT® Safety Option MCB 150) 92
9.2.3 HTL Encoder Input (VLT® Safety Option MCB 151) 92
9.3 Outputs 93
9.3.1 Digital Output (Safe Output) 93
9.3.2 24 V Supply Output 93
9.4 Other Specifications 93
9.4.1 Ground I/O Section 93
9.4.2 Cable Cross-sections 93
9.4.3 Reset Characteristics 94
9.4.4 Response Time 94
9.4.5 Safety Characteristic Data 94
10 Appendix 96
10.1 Abbreviations 96
10.2 Conventions 97
Contents
Installation Guide | VLT® Safety Option MCB 150/151
AQ279747441421en-000101 / 130R02926 | Danfoss A/S © 2018.09

1 Introduction
1.1 Purpose of this Operating Guide
This operating guide provides information for safe installation and commissioning of the safety option. It is intended for use by
qualified personnel. Read and follow the instructions to use the option safely and professionally. Pay particular attention to the safety
instructions and general warnings. Always keep this operating guide available with the option.
1.2 Available Resources
Throughout this guide there are references to other manuals that are helpful when installing the VLT® Safety Option MCB 151/152.
2
3
MCT 10
1
e30bc961.13
++
1Installation phase: Use this installation guide and refer to VLT
AutomationDrive FC 301/FC 302 Operating Guide.
3Test phase: Use the commissioning report generated via the
MCT 10 Safe Plug-in.
2Parameterization phase: Refer to VLT® Motion Control Tool
MCT 10 Set-up Software Operating Guide.
Illustration 1: System Overview
Also refer to www.danfoss.com/en/search/?filter=type%3Adocumentation%2Csegment%3Adds for more information.
1.3 Document Version
This manual is regularly reviewed and updated. All suggestions for improvement are welcome. See document version and changes
applied in table 1.
Introduction
Installation Guide | VLT® Safety Option MCB 150/151
AQ279747441421en-000101 / 130R0292 | 7
Danfoss A/S © 2018.09

Table 1: Version and Changes Applied
Edition Remarks
MG34W4xx Editorial changes. Installation of VLT® Sensorless Safety MCB 159 added.
1.4 Type Approvals and Certifications
The following list is a selection of possible type approvals and certifications for Danfoss drives:
NOTICE
Drives of enclosure size T7 (525–690 V) are not UL listed.
089
NOTICE
The specific approvals and certification for the drive are on the nameplate of the drive. For more information, contact the local
Danfoss office or partner.
For more information on UL 508C thermal memory retention requirements, refer to the section Motor Thermal Protection in the
product-specific design guide.
For more information on compliance with the European Agreement concerning International Carriage of Dangerous Goods by Inland
Waterways (ADN), refer to section AND-compliant Installation in the product-specific design guide.
Introduction
Installation Guide | VLT® Safety Option MCB 150/151
AQ279747441421en-000101 / 130R0292
8 | Danfoss A/S © 2018.09

2 Legal Information an Safety
2.1 Legal Information
According to the Machinery Directive regulation, it is hereby stated that the original language of this operating guide is English UK.
2.2 Warranty and Liability
All claims to warranty and liability are rendered invalid if:
• The product was used contrary to the purpose for which it was intended.
• Damage can be attributed to not having followed the guidelines in the manual.
• Operating personnel are not suitably qualified.
• Any type of modification has been made (for example, exchanging components on the PCB boards, soldering work, and more).
2.3 Safety Symbols
The following symbols are used in this manual:
DANGER
Indicates a hazardous situation which, if not avoided, will result in death or serious injury.
WARNING
Indicates a hazardous situation which, if not avoided, could result in death or serious injury.
CAUTION
Indicates a hazardous situation which, if not avoided, could result in minor or moderate injury.
NOTICE
Indicates a property damage message.
2.4 Qualified Personnel
The products must only be assembled, installed, programmed, commissioned, maintained, and decommissioned by persons with
proven skills. Persons with proven skills:
Legal Information an Safety
Installation Guide | VLT® Safety Option MCB 150/151
AQ279747441421en-000101 / 130R0292 | 9
Danfoss A/S © 2018.09

• Are qualified electrical engineers, or persons who have received training from qualified electrical engineers and are suitably
experienced to operatre devices, systems, plant, and machinery in accordance with the general standards and guidelines for safety
technology.
• Are familiar with the basic regulations concerning health and safety/accident prevention.
• Have read and understood the safety guidelines given in this manual and also the instructions given in the operating guide of the
drive.
• Have good knowledge of the generic and specialist standards applicable to the specific application.
2.5 Responsibilities of Users of PDS(SR)
Context:
In EN ISO 12100, risk assessment is defined as an overall process comprising a risk analysis and a risk evaluation.
Procedure
1. Carry out a hazard and risk analysis of the application according to EN ISO 12100.
2. Ensure that the qualified personnel has experience with working in ATEX areas according to Directive 99/92/EC (also known as the
ATEX Workplace Directive).
3. Identify safety functions required, and allocate SIL to each of the functions.
4. Identify other subsystems and validate the signals and commands from those subsystems.
5. Design appropriate safety-related control systems (hardware, software, parameterization, and more).
2.6 Safety Precautions
WARNING
HIGH VOLTAGE
AC drives contain high voltage when connected to AC mains input , DC supply , or load sharing. Failure to perform installation ,
start-up, and maintenance by qualified personnel can result in death or serious injury.
-Only qualified personnel must perform installation, start-up, and maintenance.
WARNING
UNINTENDED START
When the drive is connected to the AC mains, DC supply, or load sharing, the motor may start at any time, causing risk of death,
serious injury, and equipment, or property damage. The motor may start by activation of an external switch, a fieldbus
command, an input reference signal from the LCP or LOP, via remote operation using MCT 10 Set-up software, or after a cleared
fault condition.
-Press [Off] on the LCP before programming parameters.
-Disconnect the drive from the mains whenever personal safety considerations make it necessary to avoid unintended
motor start.
-Check that the drive, motor, and any driven equipment is in operational readiness.
Legal Information an Safety
Installation Guide | VLT® Safety Option MCB 150/151
AQ279747441421en-000101 / 130R0292
10 | Danfoss A/S © 2018.09