Danfoss VLT HVAC Drive FC 102 User manual

MAKING MODERN LIVING POSSIBLE
Instruction Manual
VLT®Adjustable Frequency Drive - Safe Torque Off
www.danfoss.com/drives

Contents
1 Introduction 2
1.1 Purpose of the Manual 2
1.2 Additional Resources 2
1.3 Functional Overview 2
1.4 Approvals and Certifications 3
1.5 Symbols, Abbreviations and Conventions 4
2 Safety 5
2.1 Safety Symbols 5
2.2 Qualified Personnel 5
2.3 Safety Precautions 5
3 Installation 7
3.1 Safety Instructions 7
3.2 STO Installation 7
3.3 Installation in combination with VLT®PTC Thermistor Card MCB 112 8
4 Commissioning 9
4.1 Safety Instructions 9
4.2 Activation of STO 9
4.3 Parameter Settings for STO in Combination with VLT®PTC Thermistor Card
MCB 112 9
4.4 Automatic/Manual Restart Behavior 9
4.5 STO Commissioning Test 9
4.5.1 Restart Prevention for STO Application 10
4.5.2 Automatic Restart of STO Application 10
4.6 System Configuration Security 10
4.7 Service and Maintenance 10
5 STO Technical Data 11
Index 12
Contents Instruction Manual
MG37D222 Danfoss A/S © 09/2014 All rights reserved.

1 Introduction
1.1 Purpose of the Manual
This manual provides information for the use of Danfoss
VLT®adjustable frequency drives in functional safety
applications. The manual includes information about
functional safety standards, Danfoss VLT®adjustable
frequency drive Safe Torque Off (STO) function, and the
related installation and commissioning as well as service
and maintenance for STO.
VLT®is a registered trademark.
1.2 Additional Resources
This manual is targeted at users already familiar with the
VLT®adjustable frequency drives and is intended as a
supplement to the manuals and instructions available for
download at www.danfoss.com/BusinessAreas/DrivesSo-
lutions/Documentations/VLT+Technical+Documentation.htm.
Read the instructions shipped with the adjustable
frequency drive and/or adjustable frequency drive option
before installation of the unit and observe the instructions
for safe installation.
1.3 Functional Overview
1.3.1 Introduction
The Safe Torque Off (STO) function is a component in a
safety control system. STO prevents the unit from
generating the voltage required to rotate the motor.
NOTICE!
Select and apply the components in the safety control
system appropriately to achieve the desired 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.
The VLT®adjustable frequency drive is available with:
•Safe Torque Off (STO), as defined by EN IEC
61800-5-2
•Stop Category 0, as defined in EN 60204-1
The adjustable frequency drive integrates the STO
functionality via control terminal 37.
The VLT®adjustable frequency drive with STO functionality
is designed and approved suitable for the requirements of:
•Category 3 in EN ISO 13849-1
•Performance Level "d" in EN ISO 13849-1
•SIL 2 in IEC 61508 and EN 61800-5-2
•SILCL 2 in EN 62061
1.3.2 Products Covered and Identification
The STO function is available for the following types of
adjustable frequency drives:
•VLT®HVAC Drive FC 102
•VLT®Refrigeration Drive FC 103
•VLT®AQUA Drive FC 202
•VLT®AutomationDrive FC 301 enclosure type A1
•VLT®AutomationDrive FC 302
Identification
•Confirm that the adjustable frequency drive is
configured with STO function by checking the
unit type code on the nameplate (see Table 1.1).
Product Type Code
VLT®HVAC Drive FC 102 T or U at digit 17 of the type
code
VLT®Refrigeration Drive FC 103 T at digit 17 of the type
code
VLT®AQUA Drive FC 202 T or U at digit 17 of the type
code
VLT®AutomationDrive FC 301
enclosure type A1
T at digit 17 of the type
code
VLT®AutomationDrive FC 302 X, B or R at digit 17 of the
type code
Table 1.1 Type Code Identification
Introduction Instruction Manual
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1.4 Approvals and Certifications
More approvals and certifications are available. Contact a
local Danfoss partner.
Applied standards and compliance
Use of STO on terminal 37 requires that the user satisfies
all provisions for safety including relevant laws, regulations
and guidelines. The integrated STO function complies with
the following standards:
•EN 60204-1: 2006 Stop category 0 – uncontrolled
stop
•IEC/EN 61508: 2010 SIL2
•IEC/EN 61800-5-2: 2007
•IEC/EN 62061: 2005 SIL CL2
•EN ISO 13849-1: 2008 Category 3 PL d
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1.5 Symbols, Abbreviations and Conventions
Abbreviation Reference Description
Cat. EN ISO 13849-1 Category, level “B, 1-4”
DC Diagnostic Coverage
FIT Failure In Time: 1E-9/hour
HFT EN IEC 61508 Hardware Fault Tolerance: HFT=n means that n+1 faults could cause a loss of the safety
function
MTTFd EN ISO 13849-1 Mean Time To Failure - dangerous. Unit: years
PFH EN IEC 61508 Probability of Dangerous Failures per Hour. Consider this value if the safety device is
operated during high demand or in continuous mode of operation, where the
frequency of demands for operation made on a safety-related system is greater than
once per year.
PFD EN IEC 61508 Average probability of failure on demand, value used for low demand operation.
PL EN ISO 13849-1 Discrete level used to specify the ability of safety related parts of control systems to
perform a safety function under foreseeable conditions. Levels a-e.
SFF EN IEC 61508 Safe Failure Fraction [%]; percentage of safe failures and dangerous detected failures of
a safety function or a subsystem related to all failures.
SIL EN IEC 61508
EN IEC 62061
Safety Integrity Level
STO EN IEC 61800-5-2 Safe Torque Off
SS1 EN IEC 61800-5-2 Safe Stop 1
SRECS EN IEC 62061 Safety Related Electrical Control System
SRP/CS EN ISO 13849-1 Safety Related Parts of Control Systems
PDS/SR EN IEC 61800-5-2 Power Drive System (Safety-related)
Table 1.2 Abbreviations Related to Functional Safety
Conventions
Numbered lists indicate procedures.
Bullet lists indicate other information and descriptions of figures.
Italicized text indicates
•cross reference
•link
•parameter name
Introduction Instruction Manual
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1

2 Safety
2.1 Safety Symbols
The following symbols are used in this document:
WARNING
Indicates a potentially hazardous situation that could
result in death or serious injury.
CAUTION
Indicates a potentially hazardous situation that could
result in minor or moderate injury. It can also be used to
alert against unsafe practices.
NOTICE!
Indicates important information, including situations that
can result in damage to equipment or property.
2.2 Qualified Personnel
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
engineers and are suitably experienced to
operate 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 Instruction Manual of the adjustable
frequency drive.
•have a good knowledge of the generic and
specialist standards applicable to the specific
application.
Users of PDS(SR)s are responsible for:
•Hazard and risk analysis of the application.
•Identifying safety functions required and
allocating SIL or PLr to each of the functions.
•Other subsystems and the validity of signals and
commands from them.
•Designing appropriate safety-related control
systems (hardware, software, parameterization,
etc.).
Protective measures
•Safety engineering systems may only be installed
and commissioned by qualified and skilled
personnel.
•Install the adjustable frequency drive in an IP54
cabinet as per IEC 60529 or in an equivalent
environment. In special applications, a higher IP
degree may be necessary.
•Ensure short circuit protection of the cable
between terminal 37 and the external safety
device according to ISO 13849-2 table D.4.
•When external forces influence the motor axis
(e.g., suspended loads), additional measures (e.g.,
a safety holding brake) are required to eliminate
hazards.
2.3 Safety Precautions
See the Safety chapter in the relevant Instruction Manual
for general safety precautions.
CAUTION
After installation of STO, perform a commissioning test
as specified in chapter 4.5 STO Commissioning Test. A
passed commissioning test is mandatory after first instal-
lation and after each change to the safety installation.
WARNING
RISK OF DEATH AND SERIOUS INJURY
If external forces act on the motor, e.g., in the case of
vertical axis (suspended loads) - and an unwanted
movement, e.g., caused by gravity, could cause a hazard,
the motor must be equipped with additional measures
for fall protection. For example, mechanical brakes must
be installed additionally.
WARNING
RISK OF DEATH AND SERIOUS INJURY
STO (i.e., removal of 24 V DC voltage supply to terminal
37) does not provide electrical safety. The STO function
itself is not sufficient to implement the Emergency Off
function as defined by EN 60204-1. Emergency Off
requires measures of electrical isolation, e.g., by
switching off line power via an additional contactor.
Safety Instruction Manual
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WARNING
RISK OF ELECTRICAL SHOCK
The STO function does NOT isolate AC line voltage to the
adjustable frequency drive or auxiliary circuits. Perform
work on electrical parts of the adjustable frequency drive
or the motor only after isolating the AC line voltage
supply and waiting the length of time specified in the
Safety chapter in the relevant Instruction Manual. Failure
to isolate the AC line voltage supply from the unit and
waiting the time specified could result in death or
serious injury.
•Do not stop the adjustable frequency drive by
using the STO function. If a running adjustable
frequency drive is stopped by using the function,
the unit trips and stops by coasting. If this is not
acceptable, i.e., causes danger, stop the
adjustable frequency drive and machinery by
using the appropriate stopping mode before
using this function. Depending on the
application, a mechanical brake may be required.
•STO is suitable for performing mechanical work
on the adjustable frequency drive system or
affected area of a machine only. It does not
provide electrical safety. STO should not be used
as a control for starting and/or stopping the
adjustable frequency drive.
CAUTION
Automatic restart behavior is only allowed in one of the
two situations:
•The unintended restart prevention is
implemented by other parts of the STO instal-
lation.
•A presence in the dangerous zone can be
physically excluded when STO is not activated.
In particular, paragraph 6.3.3.2.5 of ISO 12100:
2010 must be observed.
WARNING
RISK OF DEATH AND SERIOUS INJURY
The STO function can be used for asynchronous,
synchronous and permanent magnet motors. Two faults
can occur in the power semiconductor of the adjustable
frequency drive. When using synchronous or permanent
magnet motors, a residual rotation can result from the
faults. The rotation can be calculated to angle = 360/
(number of poles). The application using synchronous or
permanent magnet motors must take this residual
rotation into consideration and ensure that it does not
pose a safety risk. This situation is not relevant for
asynchronous motors.
NOTICE!
The selection of a stop category in accordance with EN
60204-1 for each stop function must be determined by a
risk assessment:
•Stop Category 0 is achieved with immediate
removal of power to the servo, resulting in an
uncontrolled coast to stop. STO according to EN
61800-5-2 accomplishes a Stop Category 0 stop.
•Stop Category 1 is achieved with power
available to the machine servos to achieve the
stop. Power is removed from the servos when
the stop is achieved according to EN 61800-5-2
Safe Stop 1 (SS1).
•Stop Category 2 is a controlled stop with power
available to the machine servos. The stop is
followed by a holding position under power.
NOTICE!
When designing the machine application, timing and
distance should be considered for a coast to stop (Stop
Category 0 or STO). For more information regarding stop
categories, refer to EN 60204-1.
Safety Instruction Manual
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3 Installation
3.1 Safety Instructions
See chapter 2 Safety for general safety instructions.
3.2 STO Installation
For motor connection, AC line input connection, and
control wiring, follow the instructions for safe installation
in the Instruction Manual of the adjustable frequency drive.
For installation with the Ex-certified VLT®PTC Thermistor
Card MCB 112, see chapter 3.3 Installation in combination
with VLT
®
PTC Thermistor Card MCB 112.
Enable the integrated STO as follows:
1. Remove the jumper wire between control
terminals 37 and 12 or 13. Cutting or breaking
the jumper is not sufficient to avoid short-
circuiting. (See jumper on Figure 3.1)
12/13
37
130BA874.10
Figure 3.1 Jumper between Terminal 12/13 (24 V) and 37
2. Connect an external safety monitoring relay via a
NO safety function to terminal 37 (STO) and
either terminal 12 or 13 (24 V DC). Follow the
installation instructions for the safety monitoring
relay, and ensure that the safety monitoring relay
complies with Category 3 /PL “d” (ISO 13849-1) or
SIL 2 (EN 62061 and IEC 61508).
12
37
3
2
FC
4
1
130BB967.10
1Safety relay (cat. 3, PL d or SIL2)
2 Emergency stop button
3 Reset button
4 Short-circuit protected cable (if not inside installation IP54
cabinet). See ISO 13849-2 Table D.4 for further information.
Figure 3.2 Installation to Achieve a Stop Category 0 (EN
60204-1) with Safety Cat. 3/PL “d” (ISO 13849-1) or SIL 2 (EN
62061 and IEC 61508).
3. Complete wiring according to the instructions
given in the Instruction Manual of the adjustable
frequency drive.
Installation Instruction Manual
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3.3 Installation in combination with VLT®
PTC Thermistor Card MCB 112
NOTICE!
Combination of VLT®PTC Thermistor Card MCB 112 and
STO function is only available for VLT®HVAC Drive FC
102, VLT®AutomationDrive FC 302, and VLT®
AutomationDrive FC 301 enclosure type A1.
VLT®PTC Thermistor Card MCB 112 uses Terminal 37 as its
safety-related switch-off channel.
•Ensure that the output X44/12 of MCB 112 is
AND-ed with the safety-related sensor (such as
emergency stop button, safetyguard switch, etc.)
that activates STO. This means that the output to
STO terminal 37 is HIGH (24 V) only if both the
signal from MCB 112 output X44/12 and the
signal from the safety-related sensor are HIGH. If
at least one of the two signals is LOW, then the
output to terminal 37 must be LOW too.
•Ensure that the safety device with AND-logic
complies with the needed safety level.
•Short circuit protect the connection from the
output of the safety device with safe AND-logic
to the STO terminal 37, see Figure 3.3.
130BA967.11
121110987654321
37203332292719181312
DI DI
SIL 2
Safe Stop
Digital Input
e.g. Par 5-15
PTC
Sensor
X44/
Par. 5-19
Terminal 37 Safe Stop
Safety Device
Safe Input
Safe Output
Safe AND Input
Manual Restart
PTC Thermistor Card
MCB112
Non-Hazardous AreaHazardous
Area
Figure 3.3 Combination of an STO Application and an MCB
112 Application
Figure 3.3 shows a Restart input for the external safety
device. This means that in this installation, 5-19 Terminal 37
Digital Input can be set to value [7] PTC 1 & Relay W or [8]
PTC 1 & Relay A/W. Refer to VLT
®
PTC Thermistor Card MCB
112 Instruction Manual for further details.
Installation Instruction Manual
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4 Commissioning
4.1 Safety Instructions
See chapter 2 Safety for general safety instructions.
4.2 Activation of STO
The STO function is activated by removing the voltage at
terminal 37 of the adjustable frequency drive. By
connecting the adjustable frequency drive to external
safety devices providing a safe delay, an installation for a
Safe Stop 1 can be obtained. External safety devices need
to fulfill Cat./PL or SIL when connected to terminal 37. The
STO function can be used for asynchronous, synchronous,
and permanent magnet motors.
When the STO function (terminal 37) is activated, the
adjustable frequency drive issues an alarm, trips the unit,
and coasts the motor to a stop. Manual restart is required.
Use the STO function to stop the adjustable frequency
drive in emergency stop situations. In normal operating
mode when STO is not required, use the standard stop
function instead. Ensure that requirements according to
ISO 12100 paragraph 6.3.3.2.5 are fulfilled before using the
automatic restart function.
4.3 Parameter Settings for STO in
Combination with VLT®PTC Thermistor
Card MCB 112
When MCB 112 is connected, additional selections are
available for 5-19 Terminal 37 Digital Input ([4] PTC 1 Alarm
to [9] PTC 1 & Relay W/A).
•Selections [1]* Safe Stop Alarm and [3] Safe Stop
Warning are still available, but are for installations
without MCB 112 or any external safety devices.
If [1]* Safe Stop Alarm or [3] Safe Stop Warning are
selected and MCB 112 is triggered, the adjustable
frequency drive reacts with an alarm Dangerous
Failure [A72] and coasts the motor safely, without
automatic restart.
•Selections [4] PTC 1 Alarm and [5] PTC 1 Warning
are not to be selected when an external safety
device is used. Those selections are for when only
MCB 112 uses the STO.
If selection [4] PTC 1 Alarm or [5] PTC 1 Warning is
selected and the external safety device triggers
STO, the adjustable frequency drive issues an
alarm Dangerous Failure [A72] and coasts the
motor safely, without automatic restart.
•Select [6] PTC 1 & Relay A to [9] PTC 1 & Relay W/A
for the combination of external safety device and
MCB 112.
CAUTION
Selections allow for automatic restart when the external
safety device is de-activated.
Before selecting [7] PTC 1 & Relay W or [8] PTC 1 & Relay
A/W, ensure that:
•The unintended restart prevention is
implemented by other parts of the STO instal-
lation, or
•A presence in the dangerous zone can be
physically excluded when STO is not activated.
In particular, paragraph 6.3.3.2.5 of ISO
12100:2010 must be observed.
See VLT
®
PTC Thermistor Card MCB 112 Instruction Manual
for further information.
4.4 Automatic/Manual Restart Behavior
By default the STO function is set to unintended restart
prevention behavior. To terminate STO and resume normal
operation:
1. Reapply 24 V DC supply to Terminal 37.
2. Give a reset signal (via Bus, Digital I/O, or [Reset]
key).
Set the STO function to automatic restart by setting the
value of 5-19 Terminal 37 Digital Input from default value
[1]* Safe Stop Alarm to value [3] Safe Stop Warning.
Automatic restart means that STO is terminated, and
normal operation is resumed, as soon as the 24 V DC is
applied to terminal 37. No reset signal is required.
4.5 STO Commissioning Test
After installation and before first operation, perform a
commissioning test of the installation, using STO.
Perform the test again after each modification of the
installation or application involving the STO.
NOTICE!
A successful commissioning test of the STO function is
required after the initial installation, and after each
subsequent change to the installation.
Commissioning Instruction Manual
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To perform a commissioning test:
•follow the instructions in chapter 4.5.1 Restart
Prevention for STO Application for applications
without automatic restart after a safe stop, or
•follow the instructions in chapter 4.5.2 Automatic
Restart of STO Application for applications with
automatic restart after a safe stop.
4.5.1 Restart Prevention for STO
Application
Application where 5-19 Terminal 37 Digital Input is set to
default value [1]* Safe Stop Alarm or combined STO and
MCB 112 where 5-19 Terminal 37 Digital Input is set to [6]
PTC 1 & Relay A or [9] PTC 1 & Relay W/A:
1. Remove the 24 V DC voltage supply to terminal
37 using the interrupt device while the adjustable
frequency drive drives the motor (that is line
power supply is not interrupted).
2. Check that:
2a The motor coasts.
2b The mechanical brake activates (if
connected).
2c The alarm Safe Stop [A68] displays in the
local control panel (LCP), if mounted.
3. Reapply 24 V DC to terminal 37.
4. Ensure that the motor remains in the coasted
state, and the mechanical brake (if connected)
remains activated.
5. Send reset signal (via Bus, Digital I/O, or [Reset]
key).
6. Ensure that the motor becomes operational
again.
The commissioning test is successfully completed when all
the above steps are passed.
4.5.2 Automatic Restart of STO Application
Application where 5-19 Terminal 37 Digital Input is set to [3]
Safe Stop Warning or combined Safe Torque Off and MCB
112 where 5-19 Terminal 37 Digital Input is set to [7] PTC 1
& Relay W or [8] PTC 1 & Relay A/W):
1. Remove the 24 V DC voltage supply to terminal
37 by the interrupt device while the adjustable
frequency drive drives the motor (that is line
power supply is not interrupted).
2. Check that:
2a The motor coasts.
2b The mechanical brake activates (if
connected).
2c The alarm Safe Stop [A68] displays in the
local control panel (LCP), if mounted.
3. Reapply 24 V DC to terminal 37.
4. Ensure that the motor becomes operational
again.
The commissioning test is successfully completed when all
the above steps are passed.
NOTICE!
See the warning on the restart behavior in
chapter 2.3 Safety Precautions.
4.6 System Configuration Security
•Security measures are the responsibility of the
user.
•The adjustable frequency drive parameters can be
password-protected.
4.7 Service and Maintenance
Conduct a functional test every 12 months to detect any
failure or malfunction of the STO functionality.
To conduct the functional test, perform the following
steps:
1. Remove the 24 V DC voltage supply at terminal
37.
2. Check if the LCP displays the alarm Safe Stop A68.
3. Verify that the adjustable frequency drive trips
the unit.
4. Verify that the motor is coasting and comes to a
complete stop.
5. Verify that the motor cannot be started.
6. Reconnect the 24 V DC voltage supply to
terminal 37.
7. Verify that the motor is not started automatically
and restarts only by giving a reset signal (via Bus,
Digital I/O, or [Reset] key).
Commissioning Instruction Manual
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5 STO Technical Data
NOTICE!
For technical specifications and operating conditions for the adjustable frequency drive, refer to the relevant Instruction
Manual of the adjustable frequency drive.
NOTICE!
The STO signal must be SELV or PELV supplied.
European Directives
Machinery Directive
(2006/42/EC)
EN ISO 13849-1
EN IEC 62061
EN IEC 61800-5-2
EMC Directive
(2004/108/EC)
EN 50011
EN 61000-6-3
EN 61800-3
Low Voltage
(2006/95/EC)
EN 50178
EN 61800-5-1
Safety
Standards
Safety of Machinery EN ISO 13849-1, IEC 62061, IEC 60204-1
Functional Safety IEC 61508-1 to -7, IEC 61800-5-2
Safety Function IEC 61800-5-2 IEC 60204-1
Safe Torque Off (STO) Stop Category 0
Safety Performance
ISO 13849-1
Category Cat 3
Diagnostic
Coverage DC: 90% (Medium)
Mean Time to Dangerous
Failure MTTFd: 14000 years (High)
Performance Level PL d
IEC 61508 / IEC 62061
Safety Integrity Level SIL 2, SIL CL2
Probability of
Dangerous Failure
per Hour
PFH: 1E-10/h
(High Demand Mode)
Probability of
Dangerous Failure
on Demand
PFD: 1E-10
(Low Demand Mode)
Safe Failure Fraction SFF: > 99%
Hardware Fault Tolerance HFT: 0 (1oo1)
Proof Test Interval T1 20 Years
Mission time TM 20 Years
Reaction time Input to output response time Maximum 20 ms
Table 5.1 Technical Data
SISTEMA Data
Functional safety data are available from a data library for use with the SISTEMA calculation tool from the IFA (Institute for
Occupational Safety and Health of the German Social Accident Insurance), and data for manual calculation. SISTEMA is
available for download at www.danfoss.com/BusinessAreas/DrivesSolutions/SISTEMA/.
STO Technical Data Instruction Manual
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Index
A
Abbreviations........................................................................................... 4
Activation................................................................................................... 9
Alarm........................................................................................................... 9
Approvals................................................................................................... 3
Automatic restart............................................................................. 9, 10
C
Certifications............................................................................................. 3
Command.................................................................................................. 5
Commissioning test............................................................................... 9
Control system......................................................................................... 5
Conventions.............................................................................................. 4
E
External safety devices.......................................................................... 9
I
Identification............................................................................................ 2
Installation................................................................................................. 8
M
Maintenance.......................................................................................... 10
Mechanical brake................................................................................. 10
O
Output......................................................................................................... 8
P
Parameter settings................................................................................. 9
Products covered.................................................................................... 2
Q
Qualified personnel................................................................................ 5
R
Restart behavior...................................................................................... 9
Restart prevention........................................................................... 9, 10
S
Safety device............................................................................................. 8
Safety guard switch................................................................................ 8
Safety-related sensor............................................................................. 8
Selections................................................................................................... 9
Signal...................................................................................................... 5, 8
SIL CL2......................................................................................................... 3
SIL2............................................................................................................... 3
SISTEMA Data......................................................................................... 11
Standards and compliance.................................................................. 3
Switch-off channel.................................................................................. 8
Symbols...................................................................................................... 4
T
Technical data........................................................................................ 11
Termination............................................................................................... 9
Thermistor card....................................................................................... 8
U
Unintended restart prevention.......................................................... 9
Index Instruction Manual
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Index Instruction Manual
MG37D222 Danfoss A/S © 09/2014 All rights reserved. 13

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